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Note
♦ Depending on design, the threa‐
ded plates may also be connec‐
ted by means of a ring.
♦ “Cold country” vehicles (e.g.
central and northern Europe)
may be fitted with air conditioner
compressors with a smaller ca‐
pacity. On these air conditioner
compressors, the pulley is slight‐
ly different to the version shown
here (e.g. no rubber elements
-B-) ⇒ Electronic parts catalogue
(ETKA) .
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6 - Air conditioner compressor
❑ Clean the drive shaft of air conditioner compressor before fitting the pulley.
3.3
Removing air conditioning compressor
from and installing on bracket
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
Removing
– Remove noise insulation under engine ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Noise insulation; Assembly over‐
view - noise insulation .
– If necessary, remove front right wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Re‐
moving and installing front wheel housing liner .
– Remove poly V-belt ⇒ Rep. gr. 13 ; Cylinder block, pulley end;
Removing and installing poly V-belt .
– Disconnect connector -6- on air conditioner compressor -1-.
– Unscrew bolts -5- and remove air conditioner compressor
-1-.
Note
If only the ancillary bracket is to be removed, the refrigerant lines
on the air conditioner compressor must not be released.
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– Secure air conditioner compressor -1- to body with suitable
material (e.g. welding wire -2-).
Installing
The installation is carried out in reverse order of removal. Observe
the following:
– Thoroughly clean contact surfaces on air conditioner com‐
pressor and bracket.
– Insert dowel sleeves -1- into air conditioner compressor.
Note
lk
Ensure that dowel sleeves are properly seated and that contact
surfaces are clean. Improperly fitted dowel sleeves or dirty or
damaged contact surfaces can cause deviations in alignment of
air conditioner compressor and engine. In the course of operation,
misalignment will result in damage to the air conditioner com‐
pressor.
NOTICE
Risk of damage to air conditioner compressor. Refrigerant oil
may accumulate in the compression chamber of a removed air
conditioner compressor.
– After installing a new air conditioner compressor or adding
new refrigerant oil, fully turn the air conditioner compressor
10 times by hand before the poly V-belt is fitted.
Specified torques
♦ ⇒ “3.1 Assembly overview - drive unit of air conditioner com‐
pressor”, page 54
Note the following when starting engine for first time after filling
the refrigerant circuit:
– Observe notes on commissioning the air conditioning system
after installing the air conditioner compressor ⇒ Air condition‐
ing system with refrigerant R134a or ⇒ Air conditioning sys‐
tems with refrigerant R1234yf - General information; Rep. gr.
87 ; Refrigerant circuit; Renewing components .
3.4
Removing and installing air conditioner
compressor
Special tools and workshop equipment required
3. Air conditioner compressor
59
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♦ Torque wrench - V.A.G 1331-
♦ Engine bung set - VAS 6122-
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♦ Vehicle diagnostic tester
Note
♦ If a new air conditioner compressor is installed, a compressor
run-in must be carried out using ⇒ Vehicle diagnostic tester.
♦ If only ancillary bracket is to be removed, refrigerant lines on
air conditioner compressor must not be loosened ⇒ page 58 .
Removing
– If fitted, remove noise insulation beneath engine ⇒ General
body repairs, exterior; Rep. gr. 66 ; Noise insulation; Assem‐
bly overview - noise insulation .
If necessary, remove front right wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Remov‐
ing and installing front wheel housing liner .
– Remove poly V-belt ⇒ Rep. gr. 13 ; Cylinder block, pulley end;
Removing and installing poly V-belt .
Vehicles with R134a refrigerant
– Drain refrigerant circuit ⇒ Air conditioning system with R134a
refrigerant; Rep. gr. 00 ; Working with air conditioner service
station .
Vehicles with R1234yf refrigerant
– Drain refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Draining refrigerant circuit .
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Continued for all vehicles
CAUTION
Risk of freezing injury caused by escaping pressurised refrig‐
erant.
There is a risk of injury to the skin and parts of the body due to
lk
freezing.
– Wear protective gloves.
– Wear protective goggles.
– Extract refrigerant and open the refrigerant circuit immedi‐
ately afterwards.
– If more than 10 minutes have passed since the refrigerant
was extracted, repeat the extraction process before opening
the refrigerant circuit. Pressure could build up in the refrig‐
erant circuit from continued evaporation.
– For any further work, immediately seal open lines and con‐
nections with clean plugs from engine bung set - VAS 6122- .
– Unscrew bolts -3-.
– Disconnect refrigerant lines -2- and -4- from air conditioner
compressor -1-.
– Disconnect electrical connector -6-.
– Unscrew bolts -5-.
– Remove air conditioner compressor -1-.
Installing
Install in reverse order of removal, observing the following:
– If air conditioner compressor has been renewed, check poly-
V belt for damage and renew as needed ⇒ Rep. gr. 13 ;
Cylinder block, belt end; Removing and installing poly-V belt .
– Carry out function “Compressor first run” in Guided Fault Find‐
ing using ⇒ Vehicle diagnostic tester.
– Clean contact surfaces of air conditioner compressor and
holder.
3. Air conditioner compressor
61
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– Insert dowel sleeves -1- into air conditioner compressor -2-.
Note
♦ Improperly fitted dowel sleeves or dirty or damaged contact
surfaces can cause deviations in alignment of air conditioner
compressor and engine. Deviations in alignment will eventu‐
ally damage the air condition compressor.
♦ If the air conditioner compressor is renewed on account of
problems (e.g. internal damage), the refrigerant circuit must
be cleaned ⇒ Air conditioning systems with refrigerant
R1234yf - General information; Rep. gr. 87 ; Refrigerant cir‐
cuit; Renewing components or ⇒ Air conditioning system -
with R134a refrigerant .
♦ When it is removed, the air conditioner compressor contains
an indeterminate amount of refrigerant oil. For this reason it is
important to observe the notes on renewing the air conditioner
compressor ⇒ Air conditioning systems with R1234yf refrig‐
erant - General information; Rep. gr. 87 ; Refrigerant circuit;
Renewing components or ⇒ Air conditioning system - with
R134a refrigerant .
On air conditioning systems with R1234yf refrigerant
If the air conditioner compressor is replaced, the following table
gives an indication as to whether the refrigerant circuit needs to
be flushed before the new air conditioner compressor is installed.
The necessity for flushing depends on the supplier and the re‐
frigerant oil that it uses.
Supplier of replacement compressor
Denso
Mahle/Del‐ Sanden
phi
Supplier of Denso
air condi‐
Do not
flush
Flush
Flush
tioner com‐
Mahle/Del‐ Flush
Do not flush Do not
flush
Do not flush Do not
pressor in‐
stalled in
vehicle
phi
Sanden
Flush
flush
– If necessary according to table, flush refrigerant circuit ⇒ Air
conditioning systems with R1234yf refrigerant - General infor‐
mation; Rep. gr. 87 ; Refrigerant circuit; Cleaning refrigerant
circuit .
Continued for all vehicles
NOTICE
Risk of damage to air conditioner compressor. Refrigerant oil
may accumulate in the compression chamber of a removed air
conditioner compressor.
– After installing a new air conditioner compressor or adding
new refrigerant oil, fully turn the air conditioner compressor
10 times by hand before the poly V-belt is fitted.
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Rep. gr.87 - Air conditioning system
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Note the following when starting engine for first time after filling
the refrigerant circuit:
– Observe notes on bringing air conditioning system into oper‐
ation after installing air conditioner compressor ⇒ Air condi‐
tioning systems with R1234yf refrigerant - General informa‐
tion; Rep. gr. 87 ; Refrigerant circuit; Renewing components
or ⇒ Air conditioning system with R134a refrigerant; Rep. gr.
00 ; Renewing components .
– Start engine with air conditioner compressor switched off (con‐
trol lamp in A/C button is off) and wait until idling speed is
stable.
– Open dash panel vents.
– Set temperature to “Lo” on heater and air conditioning controls
- EX21- or on temperature preselection.
– Switch on air conditioner compressor (control lamp in A/C
button lights up) and let it run for at least 5 minutes with engine
at idling speed.
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Note
♦ The air conditioner compressor is driven by the poly V-belt
pulley (not fitted with a magnetic clutch).
♦ If an air conditioner compressor seizes, the overload protec‐
tion separates from the air conditioner compressor shaft. The
seizure can normally be detected by the bulges in the poly V-
belt pulley. Another indication of a seizure is abraded rubber
material around the poly V-belt pulley.
♦ The air conditioner compressor has an internal oil circuit to
ensure that the air conditioner compressor is not damaged
when the refrigerant circuit is empty. This means that approx.
3
40 to 50 cm of refrigerant oil remain in the air conditioner
compressor.
♦ Only start engine when refrigerant circuits are charged.
♦ Only start engine when refrigerant circuit has been correctly
installed. If, for example, the refrigerant lines are not connec‐
ted to the air conditioner compressor and the engine is run‐
ning, the compressor may heat up so much through internal
warming that it will be damaged beyond repair.
♦ The air conditioner compressor regulating valve - N280- is not
activated when the refrigerant circuit is empty and the air con‐
ditioner compressor idles with the engine.
♦ If it is necessary to start engine with an empty refrigerant cir‐
cuit:
♦ The refrigerant circuit must be fully assembled.
♦ At least ¼ of the quantity of refrigerant oil specified for this
refrigerant circuit must be in the air conditioner compressor.
♦ The engine speed must not exceed 2000 rpm.
♦ Run engine only as long as absolutely necessary, max.
10 min.
– Moisten new seals with refrigerant oil before installing refrig‐
erant line.
3. Air conditioner compressor
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lk
NOTICE
Risk of damage to air conditioner compressor if refrigerant cir‐
cuit is empty.
– Never start the engine if the refrigerant circuit is empty.
Vehicles with R134a refrigerant
– Charge refrigerant circuit ⇒ Air conditioning system with
R134a refrigerant; Rep. gr. 00 ; Working with air conditioner
service station .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning system with refrigerant
R134a; Rep. gr. 00 ; Detecting leaks in refrigerant circuit .
Vehicles with R1234yf refrigerant
– Charge refrigerant circuit ⇒ Air conditioning systems with re‐
frigerant R1234yf - general information; Rep. gr. 87 ; Working
with air conditioner service station; Charging refrigerant cir‐
cuit .
– Perform leakage test on re-established line connections of re‐
frigerant circuit ⇒ Air conditioning systems with refrigerant
R1234yf - general information; Rep. gr. 87 ; Refrigerant circuit;
Detecting leaks .
Specified torques
♦ ⇒ “3.1 Assembly overview - drive unit of air conditioner com‐
pressor”, page 54
3.5
Checking high-pressure safety valve on
air conditioner compressor
Check
♦ Function: protects refrigerant circuit against excessive pres‐
sures.
CAUTION
Risk of freezing injury caused by refrigerant. The high-pressure
safety valve releases refrigerant when the engine is running and
the pressure in the refrigerant circuit is too high.
There is a risk of injury on hands and other parts of the body
due to freezing.
– Wear protective gloves.
– Wear protective goggles.
– Switch off engine.
High-pressure safety valve on Denso air conditioner compressor
♦ The high-pressure safety valve -arrow- has been activated
when refrigerant oil is found in the immediate vicinity.
♦ In this case, entrust a suitable workshop to perform the work
⇒ page 7 .
Note
On air conditioner compressors from other manufacturers the
high-pressure safety valve is located in a similar position.
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Rep. gr.87 - Air conditioning system
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3.6
Removing and installing pulley
3.6.1
Removing and installing belt pulley,
Denso air conditioner compressor
Note
♦ Handle belt pulley with care. The belt pulley is sensitive to im‐
pact.
♦ If the belt pulley overload protection has deployed, check free‐
dom of movement of air conditioner compressor before re‐
newing belt pulley. If air conditioner compressor does not
rotate freely, it must be renewed.
♦ If the drive plate overload protection device has been trig‐
gered, the pulley can rotate with the outer section of the drive
plate without the air conditioner compressor shaft and the
hexagon flats attached to the drive plate (inner section of drive
plate) also rotating.
Special tools and workshop equipment required
♦ Commercially available oil filter strap wrench
Removing
– Remove poly V-belt ⇒ Rep. gr. 13 ; Cylinder block, pulley end;
Removing and installing poly V-belt .
– Pull off sealing cap -1-.
– Counterhold belt pulley with oil filter strap wrench and remove
bolts -arrows-.
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– Counterhold drive shaft -1- of air conditioner compressor and
remove nut -2-.
– Detach drive plate -3- with nut.
Note
♦ The bolts of the drive plate transmit the torque to the air con‐
ditioner compressor shaft to drive the air conditioner compres‐
sor.
♦ When the drive plate has become screwed onto the air con‐
ditioner compressor shaft so firmly that it can no longer be
loosened (the 7 mm hexagon flats can no longer transmit the
necessary torque), renew air conditioner compressor.
3. Air conditioner compressor
65
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Heating, air conditioner - Edition 06.2017
– Detach retaining ring -2-.
– Remove pulley -1-.
Installing
Install in reverse order of removal. Observe the following:
– Clean drive shaft of air conditioner compressor.
– Fit pulley onto drive shaft of air conditioner compressor. The
belt pulley must be fitted without excessive force being ap‐
plied.
– Insert retaining ring. Flat side faces air conditioner compres‐
sor.
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– Clean thread of air conditioner compressor drive shaft.
Note
The thread of the new drive plate is greased with a specified
amount of a grease by the manufacturer.
Specified torques
♦ ⇒ “3.2.1 Assembly overview - pulley, Denso air conditioner
compressor”, page 56
♦ ⇒ “3.2.2 Assembly overview - belt pulley, Sanden air condi‐
tioner compressor”, page 57
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4
Control motors
⇒ “4.2 Removing and installing temperature flap control motor
V68 with potentiometer G92 ”, page 72
⇒ “4.3 Removing and installing defroster flap control motor V107
with potentiometer G135 ”, page 75
⇒ “4.4 Removing and installing air recirculation flap control motor
V113 ”, page 79
⇒ “4.5 Removing and installing left temperature flap control motor
V158 with potentiometer G220 ”, page 83
⇒ “4.6 Removing and installing right temperature flap control mo‐
tor V159 with potentiometer G221 ”, page 87
⇒ “4.7 Removing and installing rear temperature flap control mo‐
tor V137 ”, page 90
⇒ “4.8 Removing and installing fresh air/air recirculation, air flow
flap control motor V425 with potentiometer G644 ”, page 91
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⇒ “4.9 Removing and installing front air distribution flap control
motor V426 with potentiometer for front air distribution flap control
motor G642 ”, page 96
⇒ “4.10 Removing and installing air distribution flap control motor
V428 with potentiometer G645 ”, page 101
⇒ “4.11 Removing and installing air distribution flap actuation
unit”, page 105
4.1
Overview of fitting locations - front con‐
trol motors
⇒ “4.1.2 Overview of fitting locations - front control motors, air
conditioning system with electric/manual controls, right-hand
drive vehicles”, page 69
⇒ “4.1.3 Overview of fitting locations - front control motors, Cli‐
matronic, left-hand drive vehicles”, page 70
⇒ “4.1.4 Overview of fitting locations - front control motors, Cli‐
matronic, right-hand drive vehicles”, page 71
4.1.1
Overview of fitting locations - front control motors, air conditioning system
with electric/manual controls, left-hand drive vehicles
4. Control motors
67
2024 VW Tiguan Owner's Manual
