Removing and installing electrical air conditioner compressor V470 — VW

Removing and installing electrical air conditioner compressor
V470
Special tools and workshop equipment required
Torque wrench
V.A.G 1331/ (5…50 Nm)
Air conditioner service station
Vehicle diagnostic tester
Removing
Observe safety precautions when working on the high-voltage system (see “Safety precautions when working on high-voltage system”).
Observe safety precautions (see “Safety precautions when working on air conditioning systems”).
Observe safety precautions when working in the vicinity of high-voltage components (see “Safety precautions when working in the vicinity of high-voltage components”).
Comply with notes (see “Working on refrigerant circuit”).
Observe the risk rating of the high-voltage system (repair group 00: Risk category of the high-voltage system).
DANGER
Danger to life due to high voltage.
There is a risk of severe or fatal injury due to electric shock.
The high-voltage system must be de-energised by a suitably qualified technician.
Now de-energise the high-voltage system (repair group 93: De-energising the high-voltage system).
Detach front part of front right wheel housing liner far enough to gain access to electrical air conditioner compressor
V470 (repair group 66: Wheel housing liner; Assembly overview – front wheel housing liner).
If fitted, push noise insulation of electrical air conditioner compressor
V470 (5) aside or detach it partly in order to gain access to connectors and bolts.
Using
Vehicle diagnostic tester
, initiate basic setting, then perform function "Charge refrigerant circuit".
Note
Always perform the basic setting
“Charge refrigerant circuit” using the
Vehicle diagnostic tester
, to make sure that all valves of the refrigerant circuit are opened. This is the only way to extract the complete refrigerant from the circuit.
The
Vehicle diagnostic tester must not be disconnected from the vehicle during the entire extraction, evacuation and charging process.
To prevent the intrusion of moisture, all components of the refrigerant circuit which have been opened must be sealed with suitable plugs.
Extract refrigerant with air conditioning service station
. Comply with notes (see the separate procedure).
Separate connector (2) from electric air conditioner compressor
V470 (5).
Separate high voltage cable (3) from electric air conditioner compressor
V470 (5).
Disconnect earth wire (4) from electrical air conditioner compressor
V470 (5).
CAUTION
Risk of freezing injury caused by escaping pressurised refrigerant.
There is a risk of injury to the skin and parts of the body due to freezing.
Always wear safety gloves.
Always wear safety goggles.
Extract refrigerant, and open the refrigerant circuit immediately afterwards.
If more than 10 minutes passed since the refrigerant has been extracted, do not open the refrigerant circuit prior to extracting refrigerant anew. Due to re-evaporation, pressure will be built up in the refrigerant circuit.
Disconnect refrigerant lines (1) and (6) from electrical air conditioner compressor
V470 (5).
Remove bolts (7).
Remove
electrical air conditioner compressor
V470 (5).
Installing
Installation is carried out in the reverse order. When installing, note the following:
Using
Vehicle diagnostic tester
, initiate basic setting, then perform function "Charge refrigerant circuit".
Note
Always perform the basic setting
“Charge refrigerant circuit” using the
Vehicle diagnostic tester
, to make sure that all valves of the refrigerant circuit are opened. This is the only way to charge the complete circuit.
The
Vehicle diagnostic tester must not be disconnected from the vehicle during the entire extraction, evacuation and charging process.
If the component has been renewed due to a mechanical defect (e.g. wear), purge the refrigerant circuit.
If the electrical air conditioner compressor
V470 has been renewed, the compressor run-in must be carried out using the
Vehicle diagnostic tester.
Note
The compressor run-in takes approx. 120 seconds.
Upon completion of compressor run-in, use the
Vehicle diagnostic tester to clear event memory in thermal management control unit
J1024.
Only start engine after refrigerant circuit has been assembled.
Only start engine when refrigerant circuits are charged.
Note
The contact points of the electrical air conditioner compressor
V470 and the engine must be checked prior to installation.
The contact surfaces must be clean, rust- and grease-free.
NOTICE
Risk of damage to the air conditioner compressor. Refrigerant oil may accumulate in the compression chamber of a removed air conditioner compressor.
Make sure to store the air conditioner compressor in installation position only.
WARNING
Danger to life due to high voltage.
There is a risk of severe or fatal injury due to electric shock.
The high-voltage system must be brought into operation by a suitably qualified technician.
Specified torque (see “Assembly overview - drive unit of air conditioner compressor”)