A4 2002 Jetta TDI Oil Cooler, O-Ring Replacement, AC Hoses Prevents Access

Performing the annual oil change, replacing the oil cooler o-rings (p/n 038117070A & 038117070) 195K miles.
AC compressor hoses are in front of the oil cooler cover/ 32mm nut. Cannot access with a socket wrench.
Any suggestions to access the oil cooler cover best. Could remove the AC compressor, remove radiator, remove hoses.
Am I the only one struggling with this one? I don't see a procedure in the Bentley manual.
Thanks

I recently upgraded my oil cooler. I just bent the lines slightly and made it work.

I just remove the two bolts that hold the compressor on and hang it down out of the way. Just have to remove the belt and unplug the connector. Easy.

Ya, the compressor is easy to take loose. Lots of room to pry / wiggle it out.

oilhammer said:

I just remove the two bolts that hold the compressor on and hang it down out of the way. Just have to remove the belt and unplug the connector. Easy.

Click to expand...

That's what I've done, just give the bushings in the a/c compressor a smack with a small dead blow. The compressor is a lot easier to bolt back in place after that.

Slightly loosen bolts, put rod or smaller socket on them, whack a couple of times with hammer moderately.

That retracts the sleeves, then unbolt and it comes right out. Set it on a milk crate or other support but do not disconnect the lines.

I don't recall having to do anything with the compressor, just moved the lines out of the way and I could gain acess

Me either (99.5), but apparently some models have the lines routed a bit different. One thing to keep in mind, the big nut is not on there real tight, you don't necessarily have to fit that big socket to get it off.

When I did the cooler on my 03 wagon, and on my friends 02 Golf, both AC lines were definitely a tight fit to get the socket in. Just broke it loose, and got that big dog out of there. The fun part is letting all the oil drain out. Like I said, I did have to bend the aluminum line just a smidge off the compressor to allow the socket to fit. It was the larger of the two, and I only had to move it a degree or two.

You can suck 95% of it out from the top once the filter is removed with a suitable device. Minimizes the mess underneath anyway.

KrashDH said:

I don't recall having to do anything with the compressor, just moved the lines out of the way and I could gain access

Click to expand...

I did both the '01 and '03 like that. I could fit the extension between the lines and crack it loose. It's easier to remove and install from the top.


As mentioned above, open the filter and pull it up to let the oil drain into the oil pan. Spend a few minutes before you remove the "spindle" (bolt on the bottom) and get wire and hoses as much out of the way as you can. Remove and install the cooler and spindle together, it fits through into position better.

Appreciate all the response.

AC hoses are right in front of the cover.

Sounds like the oil cooler cover/ nut is not on tight. Will try to place a low profile 32mm socket and see if I can get-er done without removing the compressor if possible. Maybe thinking it through to much - still good to figure things out prior to draining all the oil. Have a MityVac will suck out what I can from above prior.

The compressor is 2 bolts and one plug. Drop it down, you'll have tons of room and won't risk bending / breaking a refrigerant line.

In case it's not apparent, you don't need to discharge the refrigerant to do this. The lines are a fine shape to let the compressor hang down a bit.

-J