Volkswagen Workshop Service and Repair Manuals

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

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

Note:

Compressor and related parts can be removed and installed without having to open refrigerant circuit

• Alternator, compressor and P.A.S. vane pump bracket
• ◆ Removing:
• ‒ First remove alternator, compressor -8 - and P.A.S. vane pump
• ‒ Removing and installing alternator

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

• ‒ Removing and installing P.A.S. vane pump

=> Repair Group 48; Removing and installing P.A.S. vane pump, vehicles with 128 kW engine

• ◆ Installing:
• ‒ First, fit "fitted bolts" -3 - and -12-.

• Washer 8.4x16x1.6
• Fitting bolt M8x28
• ◆ 25 Nm
• Socket head combi-bolt M8x30
• ◆ 25 Nm
• Socket head combi-bolt M8x30
• ◆ 25 Nm
• Socket head combi-bolt M8x38
• ◆ 25 Nm

• Refrigerant hoses
• Compressor
• ◆ Removing:

• ‒ First remove front bumper

=> General body repairs; Repair Group 63; Servicing bumpers

• ‒ Loosen bonnet lock carrier and pull forward
• ‒ Remove headlight housing

=> Electrical system; Repair Group 94; Servicing headlights

• ‒ Remove double ribbed belts -9 -
  
• ‒ Remove alternator

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

• ‒ Loosen hexagon bolts -10 - a couple of turns and knock back threaded sleeves from compressor. Then remove hexagon bolts.

• Double ribbed belts
• ◆ Removal and installing

=> 6-cylinder injection engine, Mechanics; Repair Group 13; Removing and installing ribbed belts

• Hexagon bolt M10x112
• ◆ 45 Nm
• Socket head combi-bolt M8x30
• ◆ 25 Nm
• Fitted bolt M8x20
• ◆ 25 Nm
• Washer 8.4x16x1.6