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Air Conditioning Compressor and Condenser Replacement
 
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Pelican Technical Article:

Air Conditioning Compressor and Condenser Replacement

Steve Vernon

Time:

8 hours8 hrs

Tab:

$125 to $600

Talent:

***

Tools:

T45, T30, T27, T25, T20 Torx, 16mm, 13mm, 8mm wrench, circlip remover

Applicable Models:

VW GTI (2006-09)

Parts Required:

Compressor, Condenser, hoses and clamps as needed, refrigerant

Hot Tip:

Properly evacuate your refrigerant

Performance Gain:

Cool cabin
Disconnect the ground strap from the battery terminal (red arrow) and place the cable (yellow arrow) where it can not accidentally come in contact with the battery while working.
Figure 1

Disconnect the ground strap from the battery terminal (red arrow) and place the cable (yellow arrow) where it can not accidentally come in contact with the battery while working. For more information please see our article on battery replacement.

Compressor- Remove the ribbed drive belt and lock the tensioner in the locked position.
Figure 2

Compressor- Remove the ribbed drive belt and lock the tensioner in the locked position. Begin by marking the direction of the belt (red arrow), place a 17mm wrench (yellow arrow) on the nub on the tensioner and turn it clockwise, then insert a 3mm Allen to lock (green arrow) in position. Please see our article on replacing your ribbed drive belt for additional assistance.

Compressor- The GTI MkV uses R134A refrigerant in the system.
Figure 3

Compressor- The GTI MkV uses R134A refrigerant in the system. It is illegal and dangerous to vent this gas to the atmosphere. If you are performing work on you're A/C system make sure that you properly capture and store the refrigerant from the Schrader vales on the A/C lines (red arrows).

Compressor- You will also use the Schrader valve (red arrow) to recharge or top up your system with new or stored refrigerant.
Figure 4

Compressor- You will also use the Schrader valve (red arrow) to recharge or top up your system with new or stored refrigerant.

Compressor- If you need to change out your regulator valve you must drain the system of all refrigerant first.
Figure 5

Compressor- If you need to change out your regulator valve you must drain the system of all refrigerant first. Next remove the wiring harness and using a circlip remover, remove the circlip (red arrow), pull the regulator from the compressor. Do not leave the compressor open for extended periods of time as water in the atmosphere will be absorbed into the oil and eventually ruin the compressor. Put a little clean oil on the end of the regulator o-ring and install the new regulator and reinstall the circlip.

Compressor- If you are replacing the compressor remove the wiring connection from the regulator (yellow arrow) and then the three 13mm bolts (red arrows).
Figure 6

Compressor- If you are replacing the compressor remove the wiring connection from the regulator (yellow arrow) and then the three 13mm bolts (red arrows).

Compressor- With the refrigerant safely removed you can remove the two lines with a T45 Torx (red arrows).
Figure 7

Compressor- With the refrigerant safely removed you can remove the two lines with a T45 Torx (red arrows).

Condenser- You need to remove the radiator and intercooler to replace the condenser.
Figure 8

Condenser- You need to remove the radiator and intercooler to replace the condenser. This involves removing most of the front of the vehicle. Please see our article on intercooler replacement for details on the procedures you need to perform before replacing the condenser.

Condenser- If you have safely removed the refrigerant from the system you can remove the two T45 Torx screws (red arrows) holding the A/C lines to the condenser after draining the coolant.
Figure 9

Condenser- If you have safely removed the refrigerant from the system you can remove the two T45 Torx screws (red arrows) holding the A/C lines to the condenser after draining the coolant. This will give you a little more ease of access when working at the front of the car.

Condenser- Disconnect the pressure sensor harness from the sensor (red arrow).
Figure 10

Condenser- Disconnect the pressure sensor harness from the sensor (red arrow).

Condenser- With the intercooler removed you are left with the condenser (red arrow) attached at the front.
Figure 11

Condenser- With the intercooler removed you are left with the condenser (red arrow) attached at the front. If you disconnected the refrigerant lines (yellow arrow0 earlier you are done.

Condenser- Remove the two T45 Torx screws from the refrigerant lines to the condenser (red arrows) Congratulations you are done! Installation is the reverse of removal.
Figure 12

Condenser- Remove the two T45 Torx screws from the refrigerant lines to the condenser (red arrows) Congratulations you are done! Installation is the reverse of removal. Do not run the car while the system is open. Do not leave the system open for extended periods of time and use precautions to keep dirt or debris out of the system. Follow the instructions on the refrigerant that you purchase to recharge the system.

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Comments and Suggestions:
adi Comments: Please email me the quotation for Replacement Compressor and condensor for Golf 1.6 chasis no WVWZZZ1KZ5U017235
March 19, 2015
  Followup from the Pelican Staff: I am not the best with part numbers.

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