Compressor Refrigerant Lines, Disconnecting and Connecting

Compressor Refrigerant Lines, Disconnecting and Connecting

• Compressor is always driven when engine is running; there is no magnetic clutch. Engine is therefore not to be started unless refrigerant circuit has been properly assembled. If for example the refrigerant lines are not connected to the compressor and the engine is started then the compressor may be destroyed by the build-up of internal heat.

• Seal open pipes and connections at compressor with suitable caps (to prevent ingress of dirt and moisture).

• Do not bend, kink or stretch lines or hoses as refrigerant lines and refrigerant hoses may be damaged.

Removing

- Discharge refrigerant circuit.

- Remove the noise insulation.

- If necessary, disconnect electrical connection to Refrigerant Temperature Sensor (G454) (if present) at harness connector. Refer to => [ Refrigerant Temperature Sensor ] Refrigerant Temperature Sensor (G454).

- Remove bolts - A -.






- Disconnect refrigerant lines - B - and - C -.

• Illustration shows the arrangement on a 6 cylinder engine.

Installing

Installation is carried out in the reverse order while noting the following:

- Replace O-rings seals - D - and - E -, for correct version, refer to Electronic Parts Catalog.

- Tighten the bolts - A - and - B - to 20 Nm.

• Do not use the O-rings from the shipping caps that are installed on the connections of replacement compressor when installing lines.

• Coat the O-ring seals lightly with refrigerant oil prior to installation, refer to => [ Refrigerant Circuit O-Rings ] Refrigerant Circuit O-Rings.

• Following attachment of refrigerant pipes to compressor (and installation of compressor) check routing of pipes. They must be inserted in holders provided and not make contact with other components.

• From MY 2012, vehicles with a 6-cylinder TDI engine with running change, have an additional chafe protection - A - installed on the low pressure refrigerant line - B -. Make sure that the installation position for the chafe protection - B - to the air pipe - C - is correct.






• For vehicles in which a low pressure refrigerant line - B - is installed without chafe protection - A -, Inspect the low pressure refrigerant line - B - for damages. Install the chafe protection - A - if necessary. Refer to the Electronic Parts Catalog (ETKA).

- Evacuate refrigerant circuit and recharge again.

- Operate the A/C system after filling the refrigerant circuit, refer to => [ A/C System, Operating after Filling Refrigerant Circuit ] A/C System, Operating after Filling Refrigerant Circuit