Removing and installing compressor on vehicles with 10-cyl. FSI engine (Audi S6) — AUDI

🧭 Before you start

Fits: Audi A6 C6 (4F, 2004–2011)

• Opens: coolant, refrigerant (A/C), power steering fluid
• Special tools named: T40093/1, T40093/2, VAS 5051

Don't miss

• (Item 1) and (Item 4) can be ignored.
• Unplug the connector (1) (mark the connector to avoid possible interchange).
• So as not to damage the refrigerant pipes/hoses, take care to avoid straining, kinking or bending the pipes and hoses.
• Seal open pipes and the connections at the air conditioner compressor with suitable caps (to prevent the ingress of dirt and moisture).
• Place a cloth beneath the separating point to catch any hydraulic fluid escaping.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Drain the refrigerant circuit Air conditioner with refrigerant R134a.
2. Drain the coolant Engine, mechanics19.
3. Detach the front (1) and rear (2) engine cover (arrows).
4. Remove the left air cleaner housing Engine, mechanics24.
5. Draw off the power steering hydraulic fluid from the reservoir with the used oil collector and extractorV.A.G 1782Running gear48.

6. Screw out the bolts (2) and (3).
7. Lift off the guide tube for the dipstick (arrow). [Note: (Item 1) and (Item 4) can be ignored.]
8. Screw out the bolt (arrow) for the left engine mounting.
9. Pull off the rubber seal (1) and detach the plenum chamber cover (2).
10. Attach the support bar10-222 A with the supports T40093/1 and T40093/2 to the suspension strut domes.
11. Attach the spindles of the support bar10-222 A to the rear engine lifting eyes.
12. Pretension the engine with the spindles of the support bar.
13. Evenly unscrew the bolts and nuts (1 ... 5) on the left and right.
14. Detach the anti-roll bar with cross member Running gear40.
15. Unplug the connector (1) (mark the connector to avoid possible interchange).
16. Screw out the bolts (2, 3, 4) and detach the left engine mounting bracket with engine mounting.
17. Detach the lower left coolant hose (arrow) from the radiator.
18. Unplug the connector (arrow) at the radiator outlet coolant temperature sender G83.
19. Detach the coolant hose (2) at the bottom from the thermostat housing.
20. Screw out the bolts (arrows).
21. Detach the thermostat housing and disconnect the coolant hose (1) at the top from the thermostat housing. [Note: So as not to damage the refrigerant pipes/hoses, take care to avoid straining, kinking or bending the pipes and hoses.]
22. Screw out the bolts (1) and (2).
23. Detach the refrigerant pipes from the air conditioner compressor. [Note: Seal open pipes and the connections at the air conditioner compressor with suitable caps (to prevent the ingress of dirt and moisture).]
24. Remove the coolant hose (arrows) and move the coolant pipe upwards. [Note: Place a cloth beneath the separating point to catch any hydraulic fluid escaping.]
25. Detach the hydraulic hose (arrow) from the pipe at the left longitudinal member.
26. Screw out the bolts (arrows) and detach the left engine support.
27. Use an open-ended wrench to hold the compressor drive shaft (A) in position and turn the compressor drive unit (B) in the (direction of arrow C). [Note: The compressor drive shaft (A) is not to be turned.After unfastening the screw connection, the compressor drive shaft (A) can be pushed through the socket (E) into the drive gear.]
28. Unplug the connector (1) to the air conditioning system compressor regulating valve N280 (mark the connector to prevent interchange with the engine mounting connector).
29. Screw out the bolts (arrows).
30. Detach the air conditioner compressor. [Note: Secure all hose connections with standard clamps Electronic parts catalogue.The compressor removed contains an indeterminate amount of refrigerant oil. Attention is therefore to be paid to the notes on compressor replacement Air conditioner with refrigerant R134a.]
31. Install the compressor drive shaft (A) (in the drive gear) and check both proper attachment and the corresponding socket (E).
32. Thoroughly clean the contact surfaces at the holder (and the contact surfaces at the compressor). To do so, remove the bushings (F) from the compressor holder or from the compressor if necessary.
33. Check the connections of the compressor and the refrigerant pipes for damage or dirt .
34. Make sure the bushings (F) have been inserted in the air conditioner compressor or the holder. [Note: Pay attention to correct positioning of the bushings (F) as well as to clean contact surfaces. Incorrectly fitted bushings or dirty/damaged contact surfaces could lead to misalignment between the compressor and engine. In the course of operation, misalignment results in drive shaft or compressor damage.]
35. Attach the compressor with bolts (D) (and washers (E)) to the holder (tightening torque 25 Nm). — 25 Nm (18 lb-ft)
36. Replace the sealing rings (B) and (C).
37. Attach the refrigerant pipes to the compressor (tightening torque of bolts (A) 25 Nm). For dimensions of O-rings (B) and (C) and further information, refer to and Electronic parts catalogue. — 25 Nm (18 lb-ft)
38. After installing the compressor and before screwing in the drive shaft, crank the compressor 10 times by hand in direction of arrow (C) by way of the compressor drive unit (B) (to prevent compressor damage on initial activation). [Note: Any refrigerant oil which may have collected in the compression chamber on removing the compressor or after pouring in fresh refrigerant oil (e.g. after purging the refrigerant circuit) is forced out of the compression chamber by the cranking action.]
39. Tighten the drive shaft. Use an open-ended wrench to the hold the compressor drive shaft (A) in position and turn the compressor drive unit (B) in the direction of arrow (D) (tightening torque 60 Nm). [Note: The drive shaft (A) is not to be turned.After fitting the drive shaft (A), check the installation position of the socket (E).The socket (E) is secured in position at the power steering pump flange with a clamp to stop it slipping Electronic parts catalogue.] — 60 Nm (44 lb-ft)
40. Fit the engine support Engine, mechanics10.
41. Install the thermostat housing Engine, mechanics19.
42. Fit the engine mounting bracket Engine, mechanics40.
43. Fit the anti-roll bar Running gear40.
44. Fit the left air cleaner housing Engine, mechanics24.
45. Pour hydraulic fluid into the power steering reservoir Running gear48.
46. Re-install the other components removed.
47. Evacuate and fill the refrigerant circuit Air conditioner with refrigerant R134a.
48. Add coolant and bleed the coolant circuit Engine, mechanics19.
49. Interrogate the fault memory of the operating and display unit, Climatronic control unit J255 and erase any faults displayed "Guided fault-finding" function of vehicle diagnostic, testing and information system VAS 5051.
50. Start up the air conditioner after charging the refrigerant circuit . [Note: Also heed the notes on start-up of the air conditioner after charging Air conditioner with refrigerant R134a.]

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