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Replacing air conditioner compressor pulley ("Delphi" make) > < Detaching pulley from air conditioner compressor/re-attaching ("Zexel/Valeo" make)

A3 Mk2

Replacing air conditioner compressor pulley („Sanden“ make)
Replacing air conditioner compressor pulley („Sanden“ make)
  Note
t  Heed the notes on removal of the pulley for the „Denso“ air conditioner compressor of type „1“. These also apply to this compressor → Chapter.
t  Perform the preparatory work as described for detaching the pulley with the „Denso“ air conditioner compressor of type „1“ → Chapter.
t  There are different versions of the air conditioner compressor pulley. The type „1“ pulley is fitted on air conditioner compressors with part number 1K0 820 803 up to index „Q“. Compressors with part number 1K0 820 803 as of index „S“ are fitted with the type „2“ pulley (gradual conversion as of December 2005) → Electronic parts catalogue.
t  Vehicles with a 5-cyl. engine have 2 poly V-belts attached to the air conditioner compressor. The air conditioner compressor is therefore provided with a double-belt pulley → Electronic parts catalogue.
Replacing version „1“ pulley (fitted on vehicles with 4 and 6-cyl. engine)
   
1 - Hexagon nut
q   To unfasten and tighten the hexagon nut, hold the pulley in position with a commercially available strap wrench (with fabric strap).
q   Before screwing on, remove the old locking fluid from the hexagon nut thread and the thread of the air conditioner compressor shaft.
q   Apply locking fluid when fitting the hexagon nut (e.g. D 000 600 A2) → Electronic parts catalogue.
q   Tightening torque 25 Nm
2 - Bolt
q   To slacken off and tighten the bolts, hold the pulley in position with a commercially available strap wrench (with fabric strap).
q   Before screwing in, remove the old locking fluid from the bolt threads and the threads of the pulley.
q   Apply locking fluid when fitting the bolts (e.g. D 000 600 A2) → Electronic parts catalogue.
q   Tightening torque 4.5 Nm
3 - Drive plate
q   With overload safeguard; tripped in the event of excessive torque (e.g. stiff air conditioner compressor) and the pulley just free-wheels without driving the air conditioner compressor.
q   With rubber element for decoupling the pulley from the air conditioner compressor drive shaft and for damping vibration and noise.
4 - Washer
5 - Circlip
q   Replace
q   Fit in correct position with the bevelled side -A- facing away from the air conditioner compressor (flat side towards compressor).
q   On fitting the circlip, take care not to bend it open more than necessary.
6 - Pulley
q   Clean the air conditioner compressor flange before fitting the pulley.
7 - Air conditioner compressor
q   Different models may be fitted depending on the engine version and country version of the vehicle → Electronic parts catalogue.
q   Clean the air conditioner compressor flange before fitting the pulley.

Replacing version „2“ pulley (fitted on vehicles with 4 and 6-cyl. engine)
  Note
As of Model Year 2008, air conditioner compressors with a smaller capacity are gradually being fitted on vehicles for „cold countries“ (e.g. central and northern Europe). The pulley on these air conditioner compressors only differs slightly from the version shown here (the rubber elements -B- are not provided as vibration dampers for example) → Electronic parts catalogue.
   
1 - Hexagon nut
  Note
A plastic cap is additionally fitted to protect the thread of the compressor shaft (this cap is not shown in the illustration).
q   To unfasten and tighten the hexagon nut, hold the pulley in position with a commercially available strap wrench (with fabric strap).
q   Before screwing on, remove the old locking fluid from the hexagon nut thread and the thread of the air conditioner compressor shaft.
q   Apply locking fluid when fitting the hexagon nut / bolt (e.g. D 000 600 A2) → Electronic parts catalogue.
q   Tightening torque for hexagon nut 25 Nm
2 - Bolt
q   To slacken off and tighten the bolts, hold the pulley in position with a commercially available strap wrench (with fabric strap).
q   Tightening torque 12 Nm
q   Before screwing in, remove the old locking fluid from the bolt threads and the threads of the pulley.
q   Apply locking fluid when fitting the bolts (e.g. D 000 600 A2) → Electronic parts catalogue.
3 - Drive plate
q   With overload safeguard (attachment of spring elements); this is tripped in the event of excessive torque (e.g. stiff air conditioner compressor) and the pulley just free-wheels without driving the air conditioner compressor.
q   The spring elements of the drive plate dampen vibrations and reduce noise.
4 - Circlip
q   Replace
q   Fit in correct position with the bevelled side -A- facing away from the air conditioner compressor (flat side towards compressor).
q   On fitting the circlip, take care not to bend it open more than necessary.
5 - Pulley
q   Clean the air conditioner compressor flange before fitting the pulley.
q   With rubber elements -B- and threaded plates -C- for isolating the pulley from the air conditioner compressor drive shaft (the rubber elements dampen vibrations and reduce noise).
  Note
Depending on the version, the threaded plates -C- may also be linked by way of a ring.
6 - Air conditioner compressor
q   Different models may be fitted depending on the engine version and country version of the vehicle → Electronic parts catalogue.
q   Clean the air conditioner compressor flange before fitting the pulley.

Replacing version „3“ pulley (fitted on vehicles with 5-cyl. TFSI engine)
   
1 - Hexagon nut
  Note
A plastic cap may additionally be fitted to protect the thread of the compressor shaft (this cap is not shown in the illustration).
q   To unfasten and tighten the hexagon nut, hold the pulley in position with a commercially available strap wrench (with fabric strap).
q   Before screwing on, remove the old locking fluid from the hexagon nut thread and the thread of the air conditioner compressor shaft.
q   Apply locking fluid when fitting the hexagon nut (e.g. D 000 600 A2) → Electronic parts catalogue.
q   Tightening torque for hexagon nut 25 Nm
2 - Bolt
q   To slacken off and tighten the bolts, hold the pulley in position with a commercially available strap wrench (with fabric strap).
q   Tightening torque 12 Nm
q   Before screwing in, remove the old locking fluid from the bolt threads and the threads of the pulley.
q   Apply locking fluid when fitting the bolts (e.g. D 000 600 A2) → Electronic parts catalogue.
3 - Drive plate
q   With overload safeguard (attachment of spring elements); this is tripped in the event of excessive torque (e.g. stiff air conditioner compressor) and the pulley just free-wheels without driving the air conditioner compressor.
q   The spring elements of the drive plate dampen vibrations and reduce noise.
4 - Spacer
5 - Circlip
q   Replace
q   Fit in correct position with the bevelled side -A- facing away from the air conditioner compressor (flat side towards compressor)
q   On fitting the circlip, take care not to bend it open more than necessary.
6 - Double-belt pulley
q   Clean the air conditioner compressor flange before fitting the pulley.
q   With rubber elements -B- and threaded plates -C- for isolating the pulley from the air conditioner compressor drive shaft (the rubber elements dampen vibrations and reduce noise).
  Note
t  Depending on the version, the threaded plates -C- may also be linked by way of a ring.
t  On vehicles with a 5-cyl. engine 2 belts are routed over the pulley.
7 - Air conditioner compressor
q   Different models may be fitted depending on the engine version and country version of the vehicle → Electronic parts catalogue.
q   Clean the air conditioner compressor flange before fitting the pulley.

   

Replacing air conditioner compressor pulley ("Delphi" make) > < Detaching pulley from air conditioner compressor/re-attaching ("Zexel/Valeo" make)