Removing and installing compressor bracket ("Harrison" compressor with "Diavia" bracket), Engine codes AAM, ADY, ADZ, AEK — VW

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
Electrical system
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
Electrical system
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
Electrical system
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
Heating, Air conditioning

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