Heating, Ventilation Air Conditioning: Overhaul Volkswagen Passat B5 рестайлинг

4-cyl. gasoline engine, assembly

Note. The compressor bracket and related components can be removed and installed without having to open the refrigerant circuit Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures --> A/C Refrigerant System - General

Scheme 12

1 - Hex head bolt

1. M8 x 100
2. 25 Nm

2 - Washer

3 - Bracket for refrigerant hoses

4 - Hex head combination bolt

1. M8x35
2. 30 Nm

5 - Hex head combination bolt

1. M8x50
2. 30 Nm

6 - Compressor bracket

1. Removing
2. Remove ribbed belt for compressor --> «Ribbed belt for compressor - 4-cylinder gasoline engine, removing and installing»(ref-255355-S20315169802007053000000)
3. Remove compressor from bracket, swing away (leave refrigerant hoses connected) and secure in engine compartment with wire.
4. Remove compressor bracket from engine.

7 - Tensioning roller

1. Removing and installing ribbed belt --> «Ribbed belt for compressor - 4-cylinder gasoline engine, removing and installing»(ref-255355-S20315169802007053000000) .

8 - Hex socket bolt

1. M8x28
2. 23 Nm

9 - Compressor

1. Through 09.00: Zexel
2. From 10.00: Denso
3. A/C Clutch N25
4. Servicing A/C Clutch N25 (Zexel) --> «A/C Clutch N25 - Zexel, servicing»(ref-255355-S37723751872007053000000) .

1. Servicing A/C Clutch N25 (Denso) --> «A/C Clutch N25 - Denso, servicing»(ref-255355-S11827342122007053000000) .

Scheme 13

When removing the compressor from its bracket without opening the refrigerant system, secure the compressor to the lower frame member with a suitable wire (e.g.: welding rod or similar) as illustrated.

4-cylinder TDI - PD engine, assembly

Note. The compressor bracket and related components can be removed and installed without having to open the refrigerant circuit Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures --> A/C Refrigerant System - General

Scheme 14

1 - Hex head bolt

1. M8 x 100
2. 30 Nm

2 - Washer

3 - Bracket for refrigerant hoses

4 - Hex head combination bolt

1. M8x35
2. 30 Nm

5 - Hex head combination bolt

1. M8x50
2. 30 Nm

6 - Compressor bracket

1. Removing
2. Remove ribbed belt for compressor --> «Ribbed belt for compressor - 4-cylinder TDI - PD engine, removing and installing»(ref-255355-S36122244532007053000000)
3. Remove compressor from bracket, swing away (leave refrigerant hoses connected) and secure in engine compartment with wire.
4. Remove compressor bracket from engine.

7 - Tensioning roller

1. Removing and installing ribbed belt --> «Ribbed belt for compressor - 4-cylinder TDI - PD engine, removing and installing»(ref-255355-S36122244532007053000000) .

8 - Hex socket bolt

1. M8x28
2. 23 Nm

9 - Compressor

1. Denso
2. A/C Clutch N25
3. Servicing A/C Clutch N25 (Denso) --> «A/C Clutch N25 - Denso, servicing»(ref-255355-S11827342122007053000000) .

6-cyl. engine, assembly

Note. The compressor bracket and related components can be removed and installed without having to open the refrigerant circuit Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures --> A/C Refrigerant System - General Removing ribbed belt --> 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK

Scheme 15

1 - Hex head combination bolt

1. M8x26
2. 25Nm (18 ft lb)

2 - Nuts

1. M8
2. 25Nm (18 ft lb)

3 - Compressor

1. Denso
2. A/C Clutch N25
3. Removing and installing --> «A/C compressor - 6-cylinder engine, removing and installing»(ref-255355-S38384877142007053000000)
4. Servicing A/C Clutch N25 --> «A/C Clutch N25 - Denso, servicing»(ref-255355-S11827342122007053000000)

4 - Washer

5 - Hex head bolt

1. M8x88
2. 25Nm (18 ft lb)

6 - A/C Clutch N25

1. Servicing --> «A/C Clutch N25 - Denso, servicing»(ref-255355-S11827342122007053000000)

7 - Compressor bracket

1. Remove compressor first --> «A/C compressor - 6-cylinder engine, removing and installing»(ref-255355-S38384877142007053000000)

8 - Spacer sleeve

1. Qty.: 2
2. Ensure proper fit in bracket

9 - Stud

1. M8x20

8-cylinder engine, assembly

Note. The compressor bracket and related components must only be removed and installed after discharging refrigerant circuit. Use Kent-Moore ACR4 or equivalent. Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures --> A/C Refrigerant System - General The cylinder block on 8-cylinder engines is made from aluminum. Removing ribbed belt: --> 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK .

Scheme 16

1 - Screw

1. M8x25
2. 23 Nm (17 ft. lb.)
3. Qty. 4

2 - Compressor bracket

1. Removing --> «A/C compressor - 8-cylinder engine, removing and installing»(ref-255355-S16707384972007053000000) ; A/C compressor, removing and installing
2. Remove hydraulic engine mount from engine block.
3. Remove bolts from A/C compressor bracket.

3 - Spacer sleeves

1. Ensure proper fit in bracket

4 - Oil pan

5 - Engine mount support

6 - Hex head bolt

1. M10x40
2. 50 Nm (37 ft. lb.)
3. Qty. 4

7 - Hex socket bolt

1. M8x48
2. 23 Nm (17 ft. lb.)
3. Qty. 2

8 - Power steering pump bracket

9 - Hex socket bolt

1. M10x30
2. 32 Nm (24 ft. lb.)
3. Qty. 4

10 - Power steering pump

11 - Ribbed belt

1. Removing --> «13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK»(ref-255331-S25837766742007053000000) .
2. Routing.

12 - Hex socket bolt

1. M8x34
2. 23 Nm (17 ft. lb.)
3. Qty. 3

13 - Hex socket bolt

1. M8x95
2. 23 Nm (17 ft. lb.)
3. Qty. 3

14 - Compressor

1. Denso
2. Without A/C clutch
3. Removing and installing --> «A/C compressor - 8-cylinder engine, removing and installing»(ref-255355-S16707384972007053000000)

Condenser, assembly

Note. Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures --> A/C Refrigerant System - General Service refrigerant system using Kent More ACR 4 or equivalent During servicing, all couplings, fittings and related fasteners must be torqued to specifications.

Scheme 17

1 - Lock carrier

2 - Clip

1. Vehicles from 10.00

3 - Bracket

1. Vehicles from 10.00

4 - Grommet, upper

5 - Condenser

1. Removing and installing --> «Condenser, removing and installing»(ref-255355-S26855273202007053000000) .

6 - Left air guide

7 - Right air guide

8 - Bolt

1. Vehicles through 09.00
2. 8 Nm (71 in lb)
3. Qty.: 4

9 - Rubber grommet, lower

Heating and A/C unit, assembly

Note. Before carrying out any work on the A/C refrigerant system, refer to all CAUTIONS and WARNINGS in A/C refrigerant system safety measures --> A/C Refrigerant System - General Service refrigerant system using Kent More ACR 4 or equivalent During servicing, all couplings, fittings and related fasteners must be torqued to specifications. Heating and A/C unit, removing and installing --> Heating and A/C unit, removing and installing

Scheme 18

1 - Heater core

1. Removing and installing.
2. Always use new coolant after replacement.

2 - Housing, upper part

3 - Evaporator

1. Removing and installing
2. Attaching inlet/outlet seal
3. Installing seal

4 - Housing, lower part

1. With fresh/recirculating air flap
2. With central air flap