Replacing Condenser in a VW Beetle

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From the Menu select " Replacing Condenser in Beetle", Advanced, Article ID 47.


Overview


The owner of the Beetle used for this project was the victim of a pot hole on a city street. The impact resulted in a large tear to the condenser support, Also, the condenser was badly damaged. To restore the vehicle to working order, the support and the condenser had to be replaced.


The front bumper cover attached to a Beetle is a one (1) piece assembly. The steps to remove the front bumper cover, replace the condenser support,  and condenser are explained in detail  below:


Front Bumper Cover Removal


Step 1 - Drive the front wheels onto ramps (2).

Step 2 - Place wheel chocks (2) behind the rear wheels.

Step 3 - Place the gear selector in "Park" or "1st" gear.

Step 4 - Engage the hood lever in the cabin compartment.

Step 5 - Pull the hood release cable and raise the engine hood.

Step 6 - Support the hood with the hood prop.

Step 7 - Using a flat-blade screwdriver, unsnap the clip securing the head lamps for removal (See Figure 47-1).


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Figure 47-1 Head Light Clip


Note

It is not necessary to remove the storage battery to access the head lamp clip. A long flat-blade screwdriver can be used to access head lamp for removal.


Step 7 - Using a trim tool, remove the head lamp assembly, disconnect wiring harness  and set aside (See Figure 47-2).


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Figure 47-2 Head Lamp Removed


Step 8 - Starting from the drivers-side or passenger-side, remove sixteen (16) T30 screws securing the two (2) front fenders to the body of the vehicle (See Figure 47-3).


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Figure 47-3 Removing Fender Screws


Step 9 - Using a T30 socket, remove the screws inside the passenger-side wheel well (See Figure 47-4).


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Figure 47-4 Removing Screws in Inner Wheel Well


Step 10 - Using a T30 socket, remove the screws inside the drivers-side wheel well.


Note


To access the screws in the wheel well, the road shield has to be pulled back. Figure 47-5 shows the shield dismantled for assessment to the screws.


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Figure 47-5 Accessing Screws in Wheel Well


Step 11 - Use a small flat-blade screwdriver to remove the insert to access the screw for cornering lamp (See Figure 47-6). Figure 47-7 shows the lamp insert removed.


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Figure 47-6 Removing Insert to Lamp


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Figure 47-7 Lamp Insert Removed


Step 12 - Using a phillips screwdriver with No. 2 bit, remove the screw securing the lamp to fender (See Figure 47-8).


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Figure 47-8 Removing Screw to Lamp Lens


Step 13 - Remove the harness connector to lamp lens. Figure 47-9 shows the lamp and harness removed.


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Figure 47-9 Lamp Harness Connector Removed


Step 14 - Remove the harness connector to the fog lamps.

Step 15 - Remove the front bumper assembly from the vehicle and set aside.  Figure 47-10 shows the cover removed from the vehicle.


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Figure 47-10 Front Bumper Cover Removed


Step 16 - On the drivers-side remove, the bolts with a 17mm socket securing the front bumper reinforcement beam to the frame. (See Figure 47-11).


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Figure 47-11 Removing Bolts To Reinforcement Beam


Step 17 - On the passenger-side, remove the bolts with a 17mm socket securing the front bumper reinforcement beam to the frame.


Step 18 - Remove the reinforcement beam and set aside (See Figure 47-12).


Note


A helper is needed when removing the reinforcement beam from the vehicle.


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Figure 47-12 Removed Reinforcement Beam


Step 19 - Using a flat-blade screwdriver, pry off the hood cable retaining clip (See Figure 47-13).


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Figure 47-13 Removing Hood Latch Retaining Clip


Step 20 - Remove cable and  pull the handle out through the opening in the grille (See Figure 47-14).


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Figure 47-14 Removing Hood Release Handle


Step 21 - Using a T30 socket remove bolts securing hood latch plate and condenser support.


Step 22 - Remove condenser support from vehicle and set aside (See Figure 47-15).


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Figure 47-15 Removing  Condenser Support


Step 23 -Place a jack stand under the condenser and radiator for support.


Step 24 - Remove two (2) screws from bracket on the drivers-side with a T-25 socket.


Step 25 - Remove two (2) screws from bracket on the passenger-side with a T-25 socket (See Figure 47-16).


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Figure 47-16 Removing Screws to Condenser


Step 26 - Using a T25 socket, remove the bolt securing  condenser inlet fitting on drivers-side of vehicle (See Figure 47-17).


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Figure 47-17 Removing Condenser Bolt on Drivers Side of Vehicle


Step 27 - Using a T25 socket, remove the bolt securing condenser outlet fitting on passenger-side of vehicle.


Note


To separate the tubing from the fitting, wedge with a flat-blade screwdriver (See Figure 47-18).


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Figure 47-18 Separating Tubing With Screwdriver


Step 28 - Figure 47-19 shows the condenser removed from fitting.


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Figure 47-19 Condenser Fitting Removed


Step 29 - Remove the receiver-dryer from bracket.


Step 30 - Remove the damaged condenser from vehicle and set aside (See Figure 47-20). Figure 47-21 shows the damaged fins and tubing.


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Figure 47-20 Removed Damaged Condenser


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Figure 47-21 Damaged Condenser


Finishing Up


Step 31 - Position the replacement condenser and install four (4) screws using a T25 socket that were previously removed (See Figure 47-22).


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Figure 47-22 Installing Replacement Condenser


Step 32 - Position replacement receiver-dryer in bracket with screws that were previously removed (See Figure 47-23).


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Figure 47-23 Installing Condenser Receiver-Dryer


Step 33 - Using a T25 socket, install the bolt to condenser fitting on drivers-side of vehicle (See Figure 47-24).


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Figure 47-24 Installing Condenser Tubing


Step 34 - Using a T25 socket, install the bolt to condenser fitting on passenger-side of vehicle.


Step 35 -.Figure 47-25 shows the replacement condenser intalled.


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Figure 47-25 Replacement Condenser Installed


Step 36 - Position the replacement condenser support to the condenser (See Figure 47-26).


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Figure 47-26 Position Condenser Support to Condenser


Step 37 - Align support to the mounting holes  in vehicle frame.


Step 38 - Using a T30 socket, install the bolts in mounting holes to secure condenser support. Figure 47-27 shows condenser mounting bolts being installed.


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Figure 47-27 Condenser Support Being Installed


Note


The hood latch latch and plate does not come installed from the factory bolted to the replacement support. The latch plate has to be removed from the damaged support and re-installed on the replacement support (See Figure 47-28).

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Figure 47-28 Condenser Support Installed Less Hood Latch Plate


Step 39 - Using an electric drill and appropriate size bit, drill out the rivets securing the hood latch assembly (See Figure 47-29).


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Figure 47-29 Drilling Out Rivets


Step 40 - Align the hood latch assembly to the mounting holes in the condenser support (See Figure 47-29)


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Figure 47-29 Aligning Hood Latch Assembly


Step 41 - Using a T30 socket, install the mounting bolts to secure the hood latch assembly to the condenser support (See Figure 47-30).


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Figure 47-30 Installing Hood Latch Assembly


Step 42 - Re-assemble in reverse  numerical  order starting  from Step 20 and ending at Step 1.


Step 43 - Recharge the A/C system (Go to "Remove A/C Compressor" ID5, Guru).


Step 44 - Road test vehicle.


Tools and Equipment


Ramps (2)

Wheel chocks (2)

Flat-blade screwdriver

Trim tool

T30 socket

Small flat-blade screwdriver

Phillips screwdriver

No. 2 bit

17mm socket

Jack stand

T25 socket

Electric drill

Drill bits  

I CAN'T SEE THE PICTURES    

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http://www.vwtdirepair.com/joomla/index.php?option=com_content&view=article&id=47:replacing-condenser-in-beetle&catid=3:advanced&Itemid=4
Good luck!  

Hello to all

Drive the front wheels onto ramps
Place wheel chocks behind the rear wheels.
Place the gear selector in "Park" or "1st" gear.
Engage the hood lever in the cabin compartment.
Pull the hood release cable and raise the engine hood.
Support the hood with the hood prop.
Using a flat-blade screwdriver, unsnap the clip securing the head lamps for removal

Thanks for sharing  
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