Removing and installing air conditioner compressor (manufacturer Denso or Zexel) — VW

Removing and installing air conditioner compressor (manufacturer Denso or Zexel)
Removing
Note
Zexel air conditioner compressors have to be replaced by Denso air conditioner compressors. Refer to technical product information (TPI) 2011410.
A software update on the engine control unit is only required for the 1.6 l 75 kW engine with engine code BSE. These software versions are only available online via SVM (Software Version Management) and can be flashed with the code for the repair measure.
Special tools and workshop equipment required
Torque wrench
V.A.G 1331/
(5…50 Nm)
Air conditioner service station
VAS 6007A
or successor model.
Note
The refrigerant circuit must be purged with refrigerant R134a under the following circumstances:
Dirt or other contaminants are in the refrigerant circuit.
If during evacuation of a leak-tight refrigerant circuit the vacuum display is not constant on gauge (moisture in the refrigerant circuit, which generates vapour pressure).
If the refrigerant circuit has been left open for longer than normally required for repairs (e.g. following an accident).
Pressure and temperature measurements in the refrigerant circuit indicate that there is moisture in the refrigerant circuit.
There is doubt about the amount of refrigerant oil in the refrigerant circuit.
The air conditioner compressor has to be exchanged because of internal damage (e.g. noisy or lack of power).
The procedure for purging with refrigerant R134a is described in the workshop information under Heating, ventilation, air conditioning system; Air conditioning system with refrigerant R134a,
Rep. gr.
00
Technical data; Clearing refrigerant circuit of contaminants.
Notes on repair work to vehicles with air conditioning and on handling refrigerant can be found in the workshop information under Heating, ventilation, air conditioning system; Air conditioning system with refrigerant R134a
Rep. gr.
00
; Technical data.
Notes on testing equipment and tools for repair work to vehicles with air conditioning can be found in the workshop information under Heating, ventilation, air conditioning system; Air conditioning system with refrigerant R134a
Rep. gr.
00
; Technical data.
Extract refrigerant, e.g. with
air conditioner service station
VAS 6007A
before opening refrigerant circuit. Observe notes
Chapter
.
Remove noise insulation under engine
Rep. gr.
50
.
Remove front right wheel housing liner
Rep. gr.
66
.
Removing poly V-belt
Rep. gr.
13
.
Remove belt pulley of vane pump
Rep. gr.
48
Detach connector
arrow
of magnetic clutch from air conditioner compressor.
Remove bolts (22 Nm ± 1 Nm)
1
from air conditioner compressor and separate refrigerant lines from air conditioner compressor.
WARNING
Danger from escaping pressurised refrigerant!
Freezing of skin and other body parts.
Extract refrigerant and then immediately open refrigerant circuit.
If the refrigerant was extracted more than 10 minutes before the opening of refrigerant circuit, the refrigerant must be extracted again. The pressure in the circuit will increase due to subsequent evaporation.
Remove hexagon bolts (25 Nm)
2
and remove air conditioner compressor.
Installing
Note
Ensure that dowel sleeves
3
are properly seated.
Observe remarks on installation of air conditioner compressor
Chapter
.