Volkswagen Cars 2000-05

Removal & Installation

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4-Cylinder Diesel Engines




CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Discharge the air conditioning system.
  4.  
  5. Remove the injection pump, as outlined in the Fuel System Section.
  6.  
  7. Remove the alternator, as outlined in the Engine Electrical Section.
  8.  
  9. Remove the power steering pump, as outlined in the Steering Section.
  10.  
  11. Remove the bolts, then remove the compressor from the bracket.

    Click image to see an enlarged view

    Fig. Exploded view of the compressor and related components-4-cylinder diesel engines

  12.  

To install:

  1. Install the compressor and tighten the mounting bolts to 33 ft. lbs. (45 Nm).
  2.  
  3. The remainder of installation is the reverse of removal. Recharge the air conditioning system.
  4.  

4-Cylinder Gasoline Engines




CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Discharge the air conditioning system.
  4.  
  5. Remove the drive belt, as outlined in the Engine Mechanical section.
  6.  
  7. Remove the alternator, as outlined in the Engine Electrical Section.
  8.  
  9. Remove the power steering pump, as outlined in the Steering Section.
  10.  
  11. Remove the compressor mounting bolts and remove the compressor from the vehicle.

    Click image to see an enlarged view

    Fig. Exploded view of the compressor and related components-4-cylinder engines

  12.  

To install:

  1. Install the compressor and tighten the mounting bolts to 33 ft. lbs. (45 Nm).
  2.  
  3. The remainder of installation is the reverse of removal. Recharge the air conditioning system.
  4.  

6-Cylinder Engines




CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Discharge the air conditioning system.
  4.  
  5. Move lock carrier into service position, as follows:
    1. Remove the front bumper.
    2.  
    3. Tag and remove any wiring or connector that would inhibit locking the carrier.
    4.  
    5. Disconnect Bowden cable from lock.
    6.  
    7. Remove the 2 No. 2 bolts.
    8.  
    9. Remove the 4 No. 7 bolts.
    10.  
    11. Remove the 4 No. 8 bolts.
    12.  
    13. Install Guide Rods 3411.
    14.  
    15. Remove the remaining bolts and pull the lock carrier out to the stop.
    16.  
    17. To secure the lock carrier, install the appropriate M6 bolts into the rear of the lock carrier and fender.

      Click image to see an enlarged view

      Fig. Moving the lock carrier into the service position-2.8L (BDF) engine GTI and Jetta

    18.  

  6.  
  7. Remove the drive belt, as outlined in the Engine Mechanical Section.
  8.  
  9. Remove the alternator, as outlined in the Engine Electrical Section
  10.  
  11. Remove the power steering pump, as outlined in the Steering Section.
  12.  
  13. Unfasten the mounting bolts, then remove the compressor from the vehicle.

    Click image to see an enlarged view

    Fig. Exploded view of the compressor and related components-6-cylinder engines

  14.  

To install:

  1. Install the compressor and tighten the mounting bolts to 33 ft. lbs. (45 Nm).
  2.  
  3. The remainder of installation is the reverse of removal. Recharge the air conditioning system.
  4.  


CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. If replacing the compressor, discharge the refrigerant system.
    CAUTION
    Never open, service or drain the radiator or cooling system when hot; the system is under pressure when the engine is warm. Serious burns can occur from the steam and hot coolant. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  4.  
  5. Drain the engine coolant into a suitable container.
  6.  
  7. Drain the engine oil into a suitable container.
  8.  
  9. Set the lock carrier in the service position, as outlined in the Engine Mechanical Section.
  10.  
  11. Remove the drive belt, as outlined in the Engine Mechanical Section.
  12.  
  13. Remove the viscous coupling
  14.  
  15. Remove the radiator fan resistor from the left longitudinal member.

    Click image to see an enlarged view

    Fig. Remove the radiator fan resistor (2) from the left longitudinal member (1)

  16.  
  17. Remove the oil filter.
  18.  
  19. Loosen the coolant pipe securing bolts (arrows) from the oil pan and remove coolant hoses from oil cooler.

    Click image to see an enlarged view

    Fig. Unfasten the coolant pipe mounting bolts (arrows) from the oil pan, then remove the coolant hoses from the oil cooler

  20.  
  21. Remove the oil cooler.
  22.  
  23. Unfasten the nut from the bracket for the refrigerant lines.

    Click image to see an enlarged view

    Fig. Unfasten the nut (arrow) on bracket (1) for the refrigerant lines

  24.  
  25. Remove bolts for compressor, noting their locations for installation purposes.
  26.  
  27. Remove compressor from bracket
  28.  
  29. Disconnect any necessary electrical connectors and wiring.
  30.  
  31. If not replacing the compressor, swing the compressor downward (leaving refrigerant hoses connected) and secure compressor to lower frame member with a suitable piece of wire.
    WARNING
    Never let the compressor hang unsupported from the refrigerant lines!

  32.  
  33. If replacing the compressor, remove the socket head bolts from refrigerant line retainer at compressor, and remove refrigerant lines.
  34.  

To install:

  1. Installation is the reverse of the removal procedure, noting the following:
    NOTE
    If installing a replacement compressor, always use new seals for the compressor refrigerant lines.

    1. Tighten the compressor refrigerant line M8 hex socket bolts to 18 ft. lbs. (25 Nm)
    2.  

  2.  
  3. Tighten the refrigerant pipe bracket nut to 71 inch lbs. (8 Nm).
  4.  
  5. Tighten the coolant pipe securing bolts to 89 inch lbs. (10 Nm).
    1. Tighten the radiator fan resistor retainer to 71 inch lbs. (8 Nm)
    2.  
    3. Make sure the drive belt is routed and seated properly. Refer to the Engine Mechanical Section.
    4.  
    5. Evacuate and recharge refrigerant system, as outlined in this section
    6.  
    7. Perform a leak test, as outlined in this section.
    8.  

  6.  

8-Cylinder Engines




CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.

  1. Discharge the refrigerant system.
  2.  
  3. Remove the drive belt, as outlined in the Engine Mechanical Section.
  4.  
  5. Remove refrigerant line retainers from oil pan.
  6.  
  7. Remove windshield washer reservoir.
  8.  
  9. Remove power steering pump from bracket and position it aside; do not disconnect the fluid hoses from the pump.
  10.  
  11. Remove power steering pump bracket.
  12.  
  13. Remove both front stabilizer bar brackets, then pull the stabilizer bar downwards.
    NOTE
    Before removing engine mount, support the sub-frame from below.



    Click image to see an enlarged view

    Fig. Remove both front stabilizer bar brackets (2), then pull the stabilizer bar downwards

  14.  
  15. Remove left-engine mount carrier from the sub-frame.
  16.  
  17. Remove left hydraulic engine mount from carrier and engine mount support.
  18.  
  19. Remove both fasteners from the cooling fan control module and remove.

    Click image to see an enlarged view

    Fig. Remove both fasteners (arrows) from the cooling fan control module and remove

  20.  
  21. Disconnect electrical connectors and wiring as necessary.
  22.  
  23. Remove securing bolts from compressor (leave refrigerant lines on bracket).
  24.  
  25. Remove refrigerant lines from compressor and pull the compressor out downwards from the vehicle.
  26.  

To install:

  1. Installation is the reverse of the removal procedure, noting the following:
    NOTE
    Always use new seals at compressor refrigerant lines.

    1. Tighten the compressor refrigerant line hex socket bolts to 18 ft. lbs (25 Nm)
    2.  
    3. Evacuate and recharge refrigerant system, as outlined in this section
    4.  
    5. Perform a leak test, as outlined in this section.
    6.  
    7. Turn compressor 10 revolutions (clockwise) by hand.
    8.  
    9. Make sure the drive belt is routed and seated properly. Refer to the Engine Mechanical Section.
    10.  
    11. Install hydraulic engine mount to mount carrier and engine mount support and tighten the retainers to 17 ft. lbs. (23 Nm)
    12.  
    13. Install the mount carrier to the sub-frame.
    14.  
    15. Turn the ignition to the ON position, but do NOT start the engine!
    16.  

  2.  
  3. Perform the following to the A/C system:
    1. Select "Econ" mode on the Climatronic control head
    2.  
    3. Start the engine and wait until idle speed stabilizes.
    4.  
    5. Open all instrument panel vents.
    6.  
    7. Select the "Low" temperature setting on the Climatronic control head.
    8.  
    9. Select the "Auto" mode on the Climatronic control head (compressor regulation activated) and allow engine to run for 5 minutes at idle.
      WARNING
      Do NOT start the engine while the A/C system is open (lines not connected to the compressor or other A/C system components). The compressor will overhead and be damaged.

    10.  

  4.  
  5. If it is necessary to start engine with an empty refrigerant circuit, proceed as follows:
    1. Refrigerant circuit must be fully assembled/closed.
    2.  
    3. At least 1 / 4 of the prescribed refrigerant oil must be in the compressor.
    4.  
    5. The engine speed must NOT exceed 2500 rpm.
    6.  
    7. Run the engine only as long as absolutely necessary.
    8.  

  6.  

 
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