A/C Compressor And Bracket Assembly Overview: Notes

Special tools and workshop equipment required 

• Torque wrench (5-50 Nm) or equivalent VAG 1331

Fig 1: Exploded View Of A/C Compressor And Bracket -- 1.9L 4-Cylinder TDI Engine

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Bracket

   Mounting for:

   • Generator
   • Compressor
   • Power steering pump
   • Diesel Direct Fuel Injection (DFI) Pump

     Removing without opening refrigerant circuit:

     -- Remove ribbed belt RIBBED DRIVE BELT

     -- Remove Generator (GEN) Removal and Installation

     -- Remove power steering pump Removal and Installation

     -- Remove bolt -7-

     -- Remove compressor from bracket, swing away and secure in engine compartment with wire A/C COMPRESSOR, SECURING TO BODY .

     -- Remove bolts -4- and -5-

     -- Remove compressor bracket from engine.

     Installing: 

     -- Install in reverse order of removal, noting the following:

     -- Loosely install and then and torque bolts to specified value.

     -- Ribbed belt routing A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW 

2. Power steering pump
   • Removing: Removal and Installation
3. Hex head combination bolt
   • M10 X 65
   • 45 Nm
4. Hex head combination bolt
   • M10 X 45
   • 45 Nm
5. Compressor
   • Sanden SD7-V16
   • With A/C Clutch -N25-
   • A/C Clutch -N25-, servicing A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW 
6. Hex head combination bolt
   • Qty. 2
   • M10 X 112
   • 45 Nm
7. Idler pulley
   • Assembly A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW 
8. Generator (GEN)
   • Removing: Removal and Installation
9. Ribbed belt
   • Removing: RIBBED DRIVE BELT
   • Routing A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW 

Special tools and workshop equipment required 

• Torque wrench (5-50 Nm) or equivalent VAG 1331

Fig 1: Exploded View Of A/C Compressor & Bracket - 1.9L 4-Cylinder TDI-PD Engine

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Ribbed belt
   • Ribbed belt, routing A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW .
2. Hex head bolts
   • M8 X 45
   • 25 Nm
   • Qty.: 3
3. Ribbed belt tensioner
4. Ribbed belt pulley with harmonic balancer
5. Hex head bolts
   • M10 X 112
   • 45 Nm
   • Qty.: 2
6. Hex head bolts
   • M8 X 85
   • Qty.: 2
7. Generator (GEN)
   • Removing: Removal and Installation
8. Compressor
   • Sanden SD7-V16
   • With A/C Clutch -N25-
   • A/C Clutch -N25-, servicing A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW 
9. Bracket

   Mounting for:

   • Generator
   • Compressor
   • Power steering pump

     Removing without opening refrigerant circuit:

     -- Remove ribbed belt RIBBED DRIVE BELT

     -- Remove Generator (GEN) Removal and Installation

     -- Remove power steering pump Removal and Installation

     -- Remove bolts -5-

     -- Remove compressor -8- from bracket, swing away and secure in engine compartment with wire A/C COMPRESSOR, SECURING TO BODY .

     -- Remove bolts -10- (Qty.: 6)

     -- Remove compressor bracket from engine.

     Installing: 

     -- Install in reverse order of removal, noting the following:

     -- Loosely install and then and torque bolts torque bolts -10- in sequence to specified value, beginning with bolt -A-, then -B-, -C- and so on as illustrated.

     -- Ribbed belt routing A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW 

10. Hex head bolts
    • M10 X 45
    • 45 Nm
    • Qty.: 6
      NOTE:

      When installing bracket, torque bolts in sequence beginning with bolt -A-, then -B-, -C- and so on as illustrated.

11. Hex head bolts
    • M8 X 40
12. Hex head bolts
    • M8 X 40
13. Power steering pump
    • Removing: Removal and Installation
14. Ribbed belt pulley
15. Hex head bolts
    • M8 X 14
    • 25 Nm
    • Qty.: 3
16. Hex bolts
    • M8 X 37
    • 10 Nm plus a quarter turn (90 degrees)
    • Qty.: 4

Special tools and workshop equipment required 

• Torque wrench (5-50 Nm) or equivalent VAG 1331

Fig 1: Exploded View Of A/C Compressor & Bracket - 1.8L 4-Cylinder Turbo Gasoline Engine

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Bracket

   Mounting for:

   • Generator
   • Compressor
   • Power steering pump

     Removing without opening refrigerant circuit:

     -- Remove ribbed belt Removal and Installation

     -- Remove Generator (GEN) Removal and Installation

     -- Remove power steering pump Removal and Installation

     -- Remove bolts -8-

     -- Remove compressor -7- from bracket, swing away and secure in engine compartment with wire A/C COMPRESSOR, SECURING TO BODY .

     -- Remove bolt -3- where applicable.

     -- Remove bolts -4- (Qty.: 5) and -5-.

     -- Remove compressor bracket from engine.

     NOTE:

     Bracket comes in two versions A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW .

     Installing: 

     -- Install in reverse order of removal, noting the following:

     -- Loosely install all bolts.

     -- Torque bolts in sequence ton specified value A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW 

     -- Ribbed belt routing A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW 

2. Intake manifold bracket
   • Where applicable
3. Hex socket bolt
   • Where applicable
   • M10 X 70
   • 45 Nm
   • Observe installation sequence A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW .
4. Hex socket bolt
   • M10 X 45
   • 45 Nm
   • Observe installation sequence A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW .
5. Hex socket bolt
   • Only with bracket version -A- where applicable A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW .
   • M10 X 45
   • 45 Nm
   • Observe installation sequence A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW .
6. Bushing
   • Only with bracket version -A- where applicable A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW .
7. Compressor
   • Sanden SD7-V16
   • With A/C Clutch -N25-
   • A/C Clutch -N25-, servicing A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW 
8. Hex head bolt
   • M10 X 112
   • 45 Nm

Special tools and workshop equipment required 

• Torque wrench 5-50Nm VAG 1331 (or 5 - 50 Nm equivalent)

Fig 1: Exploded View Of A/C Compressor & Bracket - 2.5L 5-Cylinder Gasoline Engine

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1. Bracket

   Mounting for

   • Generator
   • Compressor
   • Power steering pump
   • Coolant pump

     Removing without opening refrigerant circuit:

     -- Remove ribbed belt Removal and Installation .

     -- Remove Generator (GEN) Removal and Installation

     -- Remove power steering pump Removal and Installation

     -- Remove bolts -7-.

     -- Remove A/C compressor from bracket and secure to body with appropriate material (e.g. welding wire) A/C COMPRESSOR, SECURING TO BODY 

     -- Remove bolts -2- through -4- and remove bracket -1- from engine.

     Installing: 

     -- Install in reverse order of removal, noting the following:

     -- Loosely install and then and torque bolts to specified value.

     -- Route ribbed belt according to diagram A/C COMPRESSOR AND BRACKET ASSEMBLY OVERVIEW 

2. Socket head bolt M8x60
   • 25 Nm
3. Socket head bolt M8x110
   • 25 Nm
4. Hex socket bolt M8x30
   • 25 Nm
   • Qty. 4
5. Dowel sleeves
   • Qty. 2
   • Ensure proper seating between bracket and A/C compressor
6. A/C compressor
   • With A/C Clutch -N25-
   • A/C Clutch -N25-, servicing A/C CLUTCH, SANDEN ASSEMBLY OVERVIEW 
7. Hex bolts M8x85
   • 25 Nm
   • Qty. 3
8. Tensioning roller
9. Hex bolt for engine support
   • 40 Nm + 90 degrees
   • Always replace
   • Qty. 2
10. Engine support
11. Dowel sleeves
    • Qty. 2