Compressor HVAC: Service and Repair

Compressor Bracket Removing And Installing







4-cylinder TDI engine

Special tools and equipment required
- Torque wrench (5-50 Nm)


NOTE: The compressor bracket and related components can be removed and installed without discharging the refrigerant circuit.


1 - Bracket for injection pump, generator, compressor and power steering pump
- Removing:
- First remove injection pump, generator and power steering pump
- Remove bolts -7- (qty. 2)
- Remove compressor from bracket and suspend with wire on body.
- Remove bolts -4- and -5-.
- Remove bracket from engine block.
2 - Injection pump
- Removing:
3 - Power steering pump
- Removing:
4 - Bolt
- M10X65
- 45 Nm (33 ft lb)
- Qty.: 4
5 - Bolt
- M10X45
- 45 Nm (33 ft lb)
- Qty.: 2
6 - Compressor
- Manufacturer: Sanden, designation: SD7V16
- Manufacturer: Zexel, designation: DCW-17D
- With A/C clutch -N25-
7 - Bolt
- M10X112
- 45 Nm (33 ft lb)
- Qty. 2
8 - Idler pulley
9 - Generator
- Removing:
10 - Ribbed belt

Fig. 1 Ribbed belt, removing (engine code ALH only)







NOTE:
- Engine codes AEG and AFP ribbed belt, removing See Repair Manual, Engine Mechanical.
- Before removing ribbed belt, mark the direction of rotation on the belt. When installing the belt be sure that it is correctly seated on the pulley.


- Apply flat ring wrench (16 mm) to hexagon of belt tensioner.
- Move wrench in direction of arrow.
- Remove ribbed belt.

Fig. 2 Idler pulley, removing and installing







1 - Cover cap
2 - 25 Nm (18 ft lb)
3 - Idler roller

Fig. 3 Ribbed belt routing (engine code ALH only)







NOTE: When installing the belt, be sure that it is correctly seated on the pulley.