Volkswagen Workshop Service and Repair Manuals

Installing Sanden compressor bracket=>Page 87-95

Special tools, workshop equipment, test and measuring appliances and aux. items required

• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ V.A.G 1332 Torque wrench (40...200 Nm)

Notes:

• ◆ Only vehicles with manual gearbox 020 are effected.
• ◆ The compressor bracket and related components can be removed and installed without having to open the refrigerant circuit.

• ◆ If the "Diavia" bracket with Harrison compressor is replaced by Sanden compressor and related bracket, then the vehicle can only be serviced in specially equipped service workshop for air conditioning systems.
• ◆ The ribbed V-belt tensioning on the "Diavia" bracket is pre-set. The tensioning pulley on the "Sanden" bracket (standard production) adjusts the ribbed V-belt automatically.

• Compressor bracket
• ◆ Part No. 037 903 141 H
• ◆ With two pressed-on bushes
• ◆ Removing and installing alternator

=> Electrical system; Repair Group 27; Removing and installing alternator

• Hexagon nut M10
• ◆ 45 Nm
• ◆ Part No. N 015 100 2

• Hexagon nut M8
• ◆ 33 Nm
• ◆ Qty. 4
• ◆ Part No. N 902 291 02
• Hexagon bolt M10x70
• ◆ 45 Nm
• ◆ Part No. N 905 970 01
• Alternator bracket
• ◆ Part No. 037 903 123
• ◆ With pressed-on bush
• ◆ Removing and installing alternator

=> Electrical system; Repair Group 27; Removing and installing alternator

• Compressor
• ◆ Part No. 1H0 820 803 J
• ◆ Removing:
• ‒ Remove alternator bracket -5 -
• ‒ Remove hexagon bolts -4 - and -14 -

• Refrigerant hose
• ◆ Compressor/expansion valve
• ◆ Part No. 1H1 820 743 P
• ◆ Removing and installing =>Fig.1
• ◆ Same part on Sanden compressor
• Refrigerant hoses
• ◆ Compressor/condenser
• ◆ Part No. 1H0 820 721 F
• ◆ With pressure relief valve
• ◆ Removing and installing =>Fig.1
• ◆ Specifically for Harrison compressor
• Hexagon bolt M10x42
• ◆ 45 Nm
• ◆ Part No. N 102 685 01
• Compressor/refrigerant hose
• ◆ 30 Nm
• ◆ Part No. 1H0 820 825

• Adapter wire (electrical)
• ◆ Air conditioner compressor/vehicle wiring harness
• ◆ Secure with cable ties to alternator wiring harness
• Ribbed belt
• ◆ Part No. 037 260 849 C
• ◆ Renewing =>Page 87-92
• Hexagon bolt M10x42
• ◆ 45 Nm
• ◆ Part No. N 102 685 01
• Hexagon bolts M10x42
• ◆ 45 Nm
• ◆ Part No. N 102 685 01
• Hexagon bolt M12x35
• ◆ 85 Nm
• ◆ Part No. N 103 244 01
• Tensioner
• ◆ Part No. 028 903 306 B

→ Fig.1     Removing and installing refrigerant hoses

•      1 -     Compressor
•      2 -     O-Rings
• Part No. 8A0 260 749 AH
• Insert into adapter before assembling
•      3 -     Adapter (30 Nm)
• Part No. 1H0 820 825
•      4 -     O-Rings
• Part No. 1H0 820 749 G
• Insert into adapter before assembling
•      5 -     Refrigerant hose
• (Expansion valve/compressor)
•      6 -     Refrigerant hose
• (Compressor/condenser)
•      7 -     Hexagon socket head bolt (30 Nm)

Renewing ribbed V-belt

•      1 -     → Ribbed V-belt for driving A/C compressor and alternator
•      2 -     Ribbed V-belt for driving coolant pump and P.A.S. vane pump

• ‒ → Fit and align ribbed V-belt on magnetic clutch. The ribbed V-belt occupies the ribs on the magnetic clutch directly to inline with compressor. Two ribs on compressor side (arrow) of magnetic clutch remain free.

Adjusting V-belt tension

Special tools, testers and auxiliary items

• ◆ VW 210 (V-belt and ribbed V-belt test unit)
• ◆ Torque wrench with 18 mm AF socket
• ◆ 18 mm AF socket

• ‒ → Place VW 210 (pre-set) on ribbed V-belt between compressor magnetic clutch and alternator.
       Pre-setting 15

• ‒ → Using an O.J. spanner -2- press tensioning pulley -1- until the plunger mark on VW 210 is covered and at same time tighten bolt -3- using torque wrench (pre-set to 85 Nm).

Installing bracket for "Sanden" compressor

Special tools, workshop equipment, test and measuring appliances and aux. items required

• ◆ V.A.G 1331 Torque wrench (5...50 Nm)

• Alternator and compressor bracket
• ◆ Part No. 037 903 139 F
• ◆ Removing and installing alternator

=> Electrical system; Repair Group 27; Removing and installing alternator

• Tensioning element for tensioner
• ◆ Part No. 037 903 315 C
• Hexagon nut M8
• ◆ Part No. N 902 291 01
• ◆ 30 Nm
• ◆ Qty. 4

• Threaded sleeve
• Refrigerant hose
• ◆ Expansion valve/compressor
• ◆ Part No. 1H1 820 743 P
• Refrigerant hose
• ◆ Compressor/condenser
• ◆ Part No. 1H0 820 721 C
• Compressor
• ◆ Part No. 1H0 820 803 D
• ◆ Removing:
• ‒ Loosen hexagon bolt -9 - a couple of turns and drive back threaded sleeve -4 - on compressor. Then remove hexagon bolts.
• Ribbed belt
• ◆ Part No. 037 260 849 C
• ◆ Removing and installing

=> Repair Group 13

• Hexagon bolt M10x112
• ◆ 45 Nm
• ◆ Part No. N 102 098 01
• Hexagon bolt M8x42
• ◆ 25 Nm
• ◆ Part No. N 010 353 3
• Tensioner
• ◆ Part No. 028 145 278 E