Compressor, removing and installing (vehicles with 8 cyl.

engine) Page 1 of 16

Audi > B6 Platform > 2002 - 2005

Heating Air Conditioning
87 - Compressor, removing and installing

Compressor, removing and installing (vehicles with 8 cyl. engine)

Removing (compressor driven via a shaft)

Discharge refrigerant circuit Refrigerant R134a - Servicing - Repair Group 87 .

Use flexible oil extractor V.A.G 1358/A to draw off power steering hydraulic fluid from .

CAUTION!

Hot vapor or hot coolant may escape on opening reservoir. Cover

cap with cloth and open carefully.

Loosen cap of coolant reservoir.

Unbolt front left wheel.

Loosen quick-release fasteners - 1 - , screw out bolts - 2 - and remove noise insulation.

Remove front bumper Body Exterior - Repair Group 63 .

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Compressor, removing and installing (vehicles with 8 cyl. engine) Page 2 of 16

Remove left air guide - arrow - in front of auxiliary cooler.

Remove right air guide - arrow - in front of auxiliary cooler.

Place drip tray V.A.G 1306 beneath engine.

Remove drain plug - arrow - at housing for thermostat and drain off coolant at engine.

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Compressor, removing and installing (vehicles with 8 cyl. engine) Page 3 of 16

Remove coolant hose at bottom of radiator - arrow - and drain off remaining coolant.

Place oil drip tray beneath hydraulic lines to rear cooling line.

Disconnect hydraulic lines to rear cooling line at lock carrier - arrows - .

Remove cover - 1 - on right of engine compartment.

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Compressor, removing and installing (vehicles with 8 cyl. engine) Page 4 of 16

Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 - at

air guide.

Remove bolts - arrows - .

Remove air guide - 2 - .

Remove coolant hose at top - arrow - of radiator.

Remove cover - 1 - on left of engine compartment.

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Compressor, removing and installing (vehicles with 8 cyl. engine) Page 5 of 16

Remove connectors - 1 - and - 2 - from bracket and disconnect.

Expose bare wires to lock carrier.

Disconnect connector - arrow - for headlights on both sides of vehicle.

Disconnect connector - arrow - for airbag sensors on left and right of lock carrier.

Expose bare wires.

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Compressor, removing and installing (vehicles with 8 cyl. engine) Page 6 of 16

Remove hood cable at lock carrier Body Exterior - Repair Group 55 .

Disconnect connector - arrow - for fan on right.

Unbolt air guides on left and right of radiator - arrows - .

Note:

To avoid damaging condenser and refrigerant lines/hoses, make sure lines and hoses
are not strained, kinked or bent.

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Compressor, removing and installing (vehicles with 8 cyl. engine) Page 7 of 16

Unbolt refrigerant line - arrow - to air conditioner compressor.

Unbolt refrigerant line - arrow - to air conditioner evaporator.

Remove bolts - arrows - at lock carrier on left and right.

Pull off hood seal at lock carrier and wing flanges.

Remove bolts at impact absorbers - arrows - on left and right.

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Compressor, removing and installing (vehicles with 8 cyl. engine) Page 8 of 16

Note:

A second technician is required to remove the lock carrier.

Remove lock carrier and set down such that it cannot fall over.

Remove rear engine cover - arrows - .

Place support bar 10 - 222 A on wing mounting flanges.

Engage hook of support bar in engine lifting eye.

Use spindle of support bar to slightly pre-tension engine (do not raise).

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Compressor, removing and installing (vehicles with 8 cyl. engine) Page 9 of 16

Remove coolant hoses at locations marked with arrows.

Remove coolant hose at housing for thermostat - arrow - .

CAUTION!

Take care not to kink or bend refrigerant lines.

Unbolt retaining clip - arrow - for refrigerant line at bracket on right.

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Compressor, removing and installing (vehicles with 8 cyl. engine) Page 10 of 16

Unbolt left bracket for refrigerant line - arrows - .

Remove bolts - 1 - and - 2 - .

Remove refrigerant lines from air conditioner compressor and seal open connections
Refrigerant lines on compressor, removing and installing .

Unbolt nuts - 1 to 4 - for anti-roll bar mount on left and right.

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Compressor, removing and installing (vehicles with 8 cyl. engine) Page 11 of 16

Unbolt nut - 2 - .

Remove bolts - 1 - and - 3 - and remove engine bracket on left.

Disconnect connector - 1 - at engine mounting on left.

Unbolt nut - 2 - and remove engine mounting.

Note:

Shown with engine removed in illustration.

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Compressor, removing and installing (vehicles with 8 cyl. engine) Page 12 of 16

Remove bolts - 1 - and - 2 - .

Note:

To stop fluid escaping, leave hose - arrow - connected to power steering.

Unbolt guide tube for dipstick at cylinder head - arrow - and lift it off.

Remove left engine support - arrows - .

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Compressor, removing and installing (vehicles with 8 cyl. engine) Page 13 of 16

Use open-ended wrench to hold compressor drive shaft - A - in position and turn
compressor drive unit - B - in direction of arrow - C - .

Note:

Drive shaft - A - must not be turned.

After loosening threaded connection, drive shaft - A - can be pushed through socket -
E - into drive pinion.

Disconnect 2-pin connector to A/C Compressor Regulator Valve N280 .

Remove bolts - D - (tightening torque 25 Nm).

Remove compressor towards front

If necessary, remove bushings - F - from compressor.

Installing

Before installing compressor Refrigerant R134a - Servicing - Repair Group 87

Note:

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Compressor, removing and installing (vehicles with 8 cyl. engine) Page 14 of 16

The compressor removed contains an indeterminate amount of refrigerant oil.

Attention is therefore to be paid to notes on compressor replacement Refrigerant
R134a - Servicing - Repair Group 87 .

Install compressor drive shaft (in drive pinion) and check both proper attachment and
corresponding socket Compressor drive shaft, removing and installing .

If necessary, remove bushings - C - from compressor bracket.

Thoroughly clean contact surfaces - A - and - B - at bracket (as well as contact surfaces
at compressor).

Fit bushings - C - in compressor bracket.

Note:

Pay attention to correct positioning of bushings - C - as well as clean contact

surfaces. Incorrectly installed bushings or dirty/damaged contact surfaces could lead
to misalignment between compressor and engine. In the course of operation,
misalignment results in drive shaft or compressor damage.

Check type of seal at connections and refrigerant lines (must be designed for same type
of seal) Connections of refrigerant lines to the components (different versions) and
Parts Catalog

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Compressor, removing and installing (vehicles with 8 cyl. engine) Page 15 of 16

Install compressor with bolts - D - (and washers - E - ) to bracket (tightening torque 25

Nm).

Install refrigerant lines to compressor (tightening torque of bolts - A - 25 Nm). For

dimensions of O-rings - B - and - C - and further information, refer to Refrigerant lines
on compressor, removing and installing .

After installation of a new compressor or after adding fresh refrigerant oil to compressor
(e.g. after blowing out refrigerant circuit), give compressor approx. 10 turns by hand by
way of compressor drive unit - B - in direction of arrow - C - before tightening drive shaft
so as to avoid compressor damage.

Tighten drive shaft. Use open-ended wrench to hold compressor drive shaft - A - in
position and turn compressor drive unit - B - in direction of arrow - D - (tightening torque
60 Nm).

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Compressor, removing and installing (vehicles with 8 cyl. engine) Page 16 of 16

Note:

Drive shaft - A - must not be turned.

After installing drive shaft - A - , check installation position of socket - E - .

Reinstall remaining components removed.

Evacuate and fill refrigerant circuit. Refrigerant R134a - Servicing - Repair Group 87

Start up air conditioner after mounting compressor A/C system, running after
mounting compressor

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