AC Compressor Bypass Pulley '02 ALH?

Naimanator

Veteran Member
Joined
May 14, 2007
Location
Davis, CA
TDI
Silver 2002 Golf GLS TDI
'02 ALH. AC not working, compressor pulley making lots of noise. I've done a lot of troubleshooting. Compressor clutch inop for a couple of reasons, not really looking to put that much work into keeping the AC going.

Does anyone know of a reputable good quality bypass pulley that can be installed in place of the AC compressor?
 

fatmobile

Veteran Member
Joined
Jul 16, 2019
Location
north iowa
TDI
an ALH M-TDI in a MK2, a 2000 Jetta, 2003 wagon
There is a way to make a bracket and move the idler,
that will allow you to run PS and alternator without the AC.
 

Naimanator

Veteran Member
Joined
May 14, 2007
Location
Davis, CA
TDI
Silver 2002 Golf GLS TDI
There is a way to make a bracket and move the idler,
that will allow you to run PS and alternator without the AC.
Thank you, but without a link to any post or plans concerning this, it's actually a fairly unhelpful response.
 

P2B

Top Post Dawg
Joined
Jan 11, 2006
Location
Toronto & Muskoka, Canada
TDI
2002 Jetta, 2003 Jetta, 2003 Jetta Wagon
Awesome. Thank you! Do you know if this can be installed with the AC compressor still in place? I.e. can I leave it in and just install the shorter belt?
Not so awesome, sorry - that belt is for cars without AC from the factory. Using it would require relocating the power steering pump in place of the compressor.

The Dorman is the only available bypass pulley I know of, and it doesn't come with installation hardware (can't use the compressor bolts). My son bought one, the bearing was noisy from the get go and failed in short order. He replaced it with a junkyard compressor.

 

Sting

Veteran Member
Joined
Jan 20, 2004
I'll offer a counter to P2B. I got the Dorman Bypass back in November 2022 when my AC compressor completely seized. I was broken down in mid-Minnesota, and I was facing at least $800 for a compressor. The service guy and I chatted and I had seen something while waiting for the tow about the AC Bypass, he said he was familiar and was willing to put it in for me. I also didn't go with a new compressor because from what i was told, when they go like that, they tend to dump metal bits into the AC lines. Even with cleaning up the lines, I was told there was a chance of bits still getting into it and wrecking it. So I really didn't see the point in spending nearly a grand on a new compressor. I mean sure, you could find a junk one that still spins, but you never know when it will go.

I had NO warning when the compressor seized.

I will agree, the bearing was noisy to start. However, I gave it a couple squirts of gear oil that I use for my motorcycle chain, and it quieted right down. Yes, you will need to find the bolts to fit... it was a shop that installed and fixed mine. When I get home I'll check the invoice and see if they put any size spec on it. I'm actually switching it from my original engine to my spare sometime this week... if I can't find the spec on paper, I'll picture and measure them.

My car got noisy before I did my timing belt, and I naturally assumed it was the Bypass... actually, it was one the timing belt roller just starting to go bad.

Honestly, I've had good luck with it. One note... it was originally designed for the Passat, so the pulley has 6 belt grooves, instead of the 5 that the ALH has. When you install the serp belt, it needs to closer to the fender, not the engine, so one groove will be "empty" on the engine side. If not, it will eat the edge of the belt within a few hundred KM. The shop didn't realize this, and honestly it probably slipped being noticed as it wasn't an immediate issue. They did pay for another belt while I was on the road.
 
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AndyBees

Top Post Dawg
Joined
May 27, 2003
Location
Southeast Kentucky
TDI
Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
A junk yard AC Compressor is worth considering. Remove the old AC Compressor, install the used Compressor, connect the hoses and then do not plug the wiring harness. If I am not mistaken, all MK4 AC Compressors are the same, gasser or diesel. But, you can do online searches and make a list of what will fit and then go shopping.

For what it is worth, I installed a China Made AC Compressor on a friend's 01 Jetta TDI about 10 years ago. It is still doing fine today. He brought it to me for the installation.
 

fatmobile

Veteran Member
Joined
Jul 16, 2019
Location
north iowa
TDI
an ALH M-TDI in a MK2, a 2000 Jetta, 2003 wagon
Thank you, but without a link to any post or plans concerning this, it's actually a fairly unhelpful response.
Sorry I don't have time to do the search for you.
Go to utube and type AC delete in the search bar. Might help to also include vw MK4 in the search terms.
 

braddies

Veteran Member
Joined
Jul 26, 2021
Location
America
TDI
03 golf ALH
If the bearing's noisy but still intact there is still the option to replace just the pulley/bearing assembly.
 

P2B

Top Post Dawg
Joined
Jan 11, 2006
Location
Toronto & Muskoka, Canada
TDI
2002 Jetta, 2003 Jetta, 2003 Jetta Wagon
OP asked for a bypass pulley, but yeah, if it was mine I'd stick an Amazon clutch and pulley on the compressor. It can be done in an hour without opening the refrigerant system. Then see what else it would take to get the AC working.

 

AndyBees

Top Post Dawg
Joined
May 27, 2003
Location
Southeast Kentucky
TDI
Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
OP asked for a bypass pulley, but yeah, if it was mine I'd stick an Amazon clutch and pulley on the compressor. It can be done in an hour without opening the refrigerant system. Then see what else it would take to get the AC working.

I agree 100%, if the OP wants to keep his AC system intact without opening it up. I've replaced several clutch assembles and as you said, it can be done in an hour. It'd take me two hours :D

Below is an eBay option. They're all made in China, and most likely the Amazon option is too.

 

AndyBees

Top Post Dawg
Joined
May 27, 2003
Location
Southeast Kentucky
TDI
Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
That's why the price has doubled recently.
That eBay price is only about $5 more than what I paid for one about 6 years ago. I carry it in my Vanagon when on road trips. My Vanagon had the OE AC Compressor until last year.

The China made AC Compressors ranged in price from around $65 to $95 for a very long time. Then, inflation inched them up into the $80 -$100 range. The last I looked they were in the $90 to $120 range depending on the vendor. The thing I've noticed with items being shipped directly from China is the free shipping is now anywhere from a token $1 to $50 depending on the item and somethings still have free shipping.
 

AndyBees

Top Post Dawg
Joined
May 27, 2003
Location
Southeast Kentucky
TDI
Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
@P2B, I'm pretty sure it was free shipping. I can go back to about 2017 in my eBay account. I may look tonight.
I mostly window shop at Amazon.

EDIT: Apparently I purchased two of them. One in 2017 with a total cost of $52. I could not see any details of the order. Then, in 2018, I purchased one for $39 total that shows Free Shipping.
 
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P2B

Top Post Dawg
Joined
Jan 11, 2006
Location
Toronto & Muskoka, Canada
TDI
2002 Jetta, 2003 Jetta, 2003 Jetta Wagon
@P2B, I'm pretty sure it was free shipping. I can go back to about 2017 in my eBay account. I may look tonight.
I mostly window shop at Amazon.

EDIT: Apparently I purchased two of them. One in 2017 with a total cost of $52. I could not see any details of the order. Then, in 2018, I purchased one for $39 total that shows Free Shipping.
... and now it's $41 + $42 shipping, so yeah, twice the price.
 

csstevej

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Joined
Aug 12, 2004
Location
north nj
TDI
2001 golf tdi 4 door auto now a manual, mine, 2000 golf 2 door M/T son's,daughters 98 NB non-TDI 2.0, 2003 TDI NB for next daughter, head repaired and on road,glutton for punishment got another tdi 2001NB,another yellow tdi NB , added an 06 NB DSG
Andy’s link shows free shipping.
 

csstevej

Top Post Dawg
Joined
Aug 12, 2004
Location
north nj
TDI
2001 golf tdi 4 door auto now a manual, mine, 2000 golf 2 door M/T son's,daughters 98 NB non-TDI 2.0, 2003 TDI NB for next daughter, head repaired and on road,glutton for punishment got another tdi 2001NB,another yellow tdi NB , added an 06 NB DSG
That’s weird……..
 

AndyBees

Top Post Dawg
Joined
May 27, 2003
Location
Southeast Kentucky
TDI
Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
Not when I open it, see screen shot above.
I have no intent to argue with you about whether or not the item has free shipping or a charge for shipping. It is listed by a vendor in the USA.
Shipping to Canada may be what you see.

My point is, the item is still available at a good price and free shipping to my address in the USA ................ China made, of course.
 

AndyBees

Top Post Dawg
Joined
May 27, 2003
Location
Southeast Kentucky
TDI
Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
$38 with free shipping if you have prime, lots less work to just change the pulley then to remove the compressor.
I don't have "Amazon Prime" because I do not buy enough from them to justify the Fee.

Yes, the assembly can be replaced without removed the AC Compressor. I've done several of them without removing Compressor.
 

P2B

Top Post Dawg
Joined
Jan 11, 2006
Location
Toronto & Muskoka, Canada
TDI
2002 Jetta, 2003 Jetta, 2003 Jetta Wagon
I don't have "Amazon Prime" because I do not buy enough from them to justify the Fee.
Same here but my better half buys more crap than you can poke a stick at ;)

I just send her the link to what I want. Most of the time the price and/or shipping cost/time changes when she opens the link 🤷‍♂️
 

BobnOH

not-a-mechanic
Joined
May 29, 2004
Location
central Ohio
TDI
New Beetle 2003 manual
Me three. No Amazon for years. I believe in the capitalist system, it's not healthy when a single company has such a large share of the market. Plus they have a lot of junk. I use sites like pricegrabber.com to find better prices. Amazon is handy to find stuff.
 

AndyBees

Top Post Dawg
Joined
May 27, 2003
Location
Southeast Kentucky
TDI
Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
Me three. No Amazon for years. I believe in the capitalist system, it's not healthy when a single company has such a large share of the market. Plus they have a lot of junk. I use sites like pricegrabber.com to find better prices. Amazon is handy to find stuff.
Yeah, I use Amazon to "window" shop. I have an account and a very long "wish list" for reference.
 

Yaro

Member
Joined
May 19, 2025
Location
Socal
TDI
2013 Jetta TDI
I’ve seen a few folks go the bypass route, check out the AC delete pulley kit from Metalnerd or IDParts. They’re well-regarded in the community for quality. Should bolt right in place of the compressor on the ALH.
 

P2B

Top Post Dawg
Joined
Jan 11, 2006
Location
Toronto & Muskoka, Canada
TDI
2002 Jetta, 2003 Jetta, 2003 Jetta Wagon
I’ve seen a few folks go the bypass route, check out the AC delete pulley kit from Metalnerd or IDParts. They’re well-regarded in the community for quality. Should bolt right in place of the compressor on the ALH.
Links?

No matching products found when searching for AC delete at Metalnerd and IDParts sites.
 
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