SEAT Workshop Service and Repair Manuals

Air conditioner compressor pulley   Note Different versions of the air conditioner compressors from different manufacturers may be fitted depending on the engine and production period → Electronic spare parts catalogue.   WARNING Before commencing work on the compressors of the air conditioning system, disconnect the battery → Electrical system; Rep. gr.27. Exploded view of „Denso“ air conditioner compressor pulley - version „1“ → Anchor Removing and installing pulley on „Denso“ air conditioner compressor - version „1“ → Anchor. Assembly overview of „Denso“ air conditioner compressor pulley - version „2“ → Anchor Removing and installing pulley on „Denso“ air conditioner compressor - version „2“ → Anchor. Assembly overview of „Denso“ air conditioner compressor pulley - version „3“ → Anchor Removing and installing pulley on „Denso“ air conditioner compressor - version „3“ → Anchor. Assembly overview of „Sanden“ („Delphi“) air conditioner compressor pulleys → Anchor Air conditioner compressor „Sanden“ („Delphi“) → Anchor Assembly overview of „Zexel“„Valeo“ air conditioner compressor pulleys → Anchor Installation and removal of the „Zexel“„Valeo“ air conditioner compressor pulleys → Anchor Special tools and workshop equipment required

t  Torque wrench kit -SAT 8010-

t  Counterhold tool -T20018B- Assembly overview of „Denso“ air conditioner compressor pulley - version „1“

This type of pulley is installed e.g. on vehicles with air conditioner compressor version „7 SEU 16“.

1 -

Bolt.

q

Replace

q

20 Nm

2 -	Drive plate

q	Different versions → Electronic parts catalogue

q	Detaching and attaching → Anchor

q	With overload protection device; triggered if torque is too great (e.g. if air conditioner compressor cannot rotate freely) causing pulley to free-wheel without driving air conditioner compressor

3 -

Circlip

q

Replace

q	Ensure correct positioning - flat side facing air conditioner compressor

4 -

Pulley

q	Different versions → Electronic parts catalogue

q	Detaching and attaching → Anchor

q	Rubber element of pulley is triggered if torque is too great (e.g. if air conditioner compressor cannot rotate freely) causing pulley to free-wheel without driving air conditioner compressor

Under certain conditions (e.g. rough engine running), the rubber element of the pulley may be tripped when there is no air conditioner compressor or refrigerant circuit fault.

5 -	Air conditioning compressor

q	Clean the air conditioner compressor drive shaft before fitting the pulley

Removing and installing pulley on „Denso“ air conditioner compressor - version „1“.   Note t  If the pulley overload safeguard has been tripped, check the freedom of movement of the air conditioner compressor before replacing the pulley. Replace the entire air conditioner compressor if it is stiff. t  The pulley overload protection function is described e.g. in → No.240. t  The air conditioner compressor can be detached from the bracket at the engine and re-attached without opening up the refrigerant lines.

Detaching –  Remove poly V-belt → Rep. gr.13. –  Provide support with a commercially available two-hole pin wrench -C- (pin diameter 5.0 mm) at the drive plate -B- and screw out the bolt -A-.   Note If the pulley cannot be detached with the air conditioner compressor in position, detach the air conditioner compressor with the refrigerant lines connected → Chapter.

–  Carefully and evenly prise off the drive plate -A- using 2 screwdrivers -B-.   Note t  When prising off drive plate -A-, take care not to damage collar of pulley -C-. t  There are different versions of the pulley -C- and the drive plate -A-. For correct version, refer to → Electronic spare parts catalogue.

–  Remove the circlip -A-. –  Detach the pulley -B-. Installing l  Tightening torque → Anchor Installation is carried out in the reverse order. When installing, note the following:   Note Replace the circlip. –  Air conditioner compressor flange; clean before pushing on pulley –  Attach the pulley to the air conditioner compressor flange. l  without having to exert force. –  Insert the circlip -A- in the correct position. l  The bevelled side -A- facing away from the air conditioner compressor (flat side towards air conditioner compressor). –  Install air conditioner compressor → Chapter. –  Install poly V-belt → Rep. gr.13. Assembly overview of „Denso“ air conditioner compressor pulley - version „2“

This type of pulley is installed e.g. on vehicles with air conditioner compressor version „7 SEU 17“.

1 -

Circlip

q	With vulcanised rubber disc

q	Remove carefully using a small screwdriver or pointed-nose pliers (paying particular attention to the pulley)

q	The vulcanised rubber disc is designed to provide noise insulation with low compressor output when the engine is idling

2 -	Drive plate

q	Different versions → Electronic parts catalogue

q	Detaching and attaching → Anchor

q	Screwed to the air conditioner compressor drive shaft

q	With overload protection device; triggered if torque is too great (e.g. if air conditioner compressor cannot rotate freely) causing pulley to free-wheel without driving air conditioner compressor

q	A plastic disc may have been bonded on, depending on production period → Anchor.

q

35 Nm

3 -

Circlip

q

Replace

q	Ensure correct positioning - flat side facing air conditioner compressor

4 -

Shim

q	Dimension: 17.5 x 10 x 3 mm

5 -	Rubber elements

q

6 units

q	Ensure correct positioning → Anchor

q	Decouples pulley from drive shaft of air conditioner, damping vibration and noise

6 -

Pulley

q	Different versions → Electronic parts catalogue

q	Made of plastic, sensitive to impact

q	Detaching and attaching → Anchor

7 -	Air conditioning compressor

q	Clean the air conditioner compressor drive shaft before fitting the pulley

Removing and installing pulley on „Denso“ air conditioner compressor - version „2“.   Note t  If the pulley overload safeguard has been tripped, check the freedom of movement of the air conditioner compressor before replacing the pulley. Replace the entire air conditioner compressor if it is stiff. t  The air conditioner compressor can be detached from the holder for the ancillaries and re-attached without opening up the refrigerant lines. t  The pulley is made from plastic and is quite fragile, for this reason handle it with great care. t  A plastic disc may have been affixed to the pulley drive plate to minimise noise → Electronic parts catalogue. t  This plastic disc -B- reduces the rattling (castanet-like) noise which can occur at the pulley, particularly in the case of vehicles with TDI engine with the air conditioner switched off (air conditioner compressor deactivated). The noise is scarcely perceptible in air conditioner full load operation.

Detaching –  Remove poly V-belt → Rep. gr.13. –  Use a small screwdriver or pointed-nose pliers to carefully remove the circlip -A- (with vulcanised rubber disc).   Caution Risk of damage. t  Take care not to damage the pulley on removing the circlip. t  Damaged pulleys must be replaced. –  Use a commercially available Allen key to support the drive shaft of the air conditioner compressor -B-.   Note Depending on the version of the air conditioner compressor, use can be made of a socket wrench from the shock absorber set -T10001- to provide support for the drive shaft. –  Turn the drive plate -C- with the pulley -D- in -arrow direction E-. –  Detach the drive plate.

–  Remove the circlip -A-. –  Detach pulley -B-. Installing l  Tightening torque → Anchor Installation is carried out in the reverse order. When installing, note the following: –  Clean the air conditioner compressor drive shaft before fitting the pulley. –  Attach the pulley to the air conditioner compressor drive shaft. l  without having to exert force. –  Insert the circlip -A- in the correct position. l  Fit with the bevelled side -C- facing away from the air conditioner compressor - flat side towards air conditioner compressor. –  Insert rubber elements -D- into pulley -B- as shown. –  For fitting the drive plate, moisten the rubber elements with a small quantity of tyre assembly paste or soap solution for example to provide lubrication.

–  Insert the drive plate -C- in the rubber elements until these make contact with the drive shaft -B- of the air conditioner compressor. –  Position the drive plate on the air conditioner compressor flange and screw on in -arrow direction F- using a commercially available strap wrench (with fabric strap) whilst providing support with an Allen key.   Note Depending on the version of the air conditioner compressor, use can be made of a socket wrench from the shock absorber set -T10001- to provide support for the drive shaft. –  Fit the circlip -A- (with rubber disc). –  Install poly V-belt → Rep. gr.13. Assembly overview of „Denso“ air conditioner compressor pulley - version „3“

This type of pulley is installed e.g. on vehicles with air conditioner compressor version „6 SEU 14“.

1 -	Sealing cap

2 -	Drive plate

q

Replace

q	Screwed to the air conditioner compressor drive shaft

Thread of new drive plate has been lubricated at factory with a pre-determined amount of a specific grease.

q	Different versions → Electronic parts catalogue

q	With overload protection device; triggered if torque is too great (e.g. if air conditioner compressor cannot rotate freely) causing pulley to free-wheel without driving air conditioner compressor

q	With rubber elements for decoupling the pulley from the air conditioner compressor drive shaft and for damping vibration and noise

q	Detaching and attaching → Anchor

q

30 Nm

3 -

Circlip

q

Replace

q	Ensure correct positioning - flat side facing air conditioner compressor

4 -

Pulley

q	Different versions → Electronic parts catalogue

q	Made of plastic, sensitive to impact

q	Detaching and attaching → Anchor

5 -	Air conditioning compressor

q	Clean the air conditioner compressor drive shaft before fitting the pulley

Removing and installing pulley on „Denso“ air conditioner compressor - version „3“.   Note t  If the pulley overload safeguard has been tripped, check the freedom of movement of the air conditioner compressor before replacing the pulley. Replace the entire air conditioner compressor if it is stiff. t  The air conditioner compressor can be detached from the holder for the ancillaries and re-attached without opening up the refrigerant lines. t  Pulley is made of plastic, is sensitive to impact and should be treated with special care.

t  If the overload safeguard of the drive plate -C- has been tripped, the pulley -E- can rotate with the outer section of the drive plate -C- without the air conditioner compressor shaft -B- and the hexagon -D- attached to the drive plate (inner section of drive plate -C-) also turning. t  The pulley is supplied as a replacement part together with the drive plate and cap, which are bolted together. The bolt is not required and can be disposed of → Electronic parts catalogue. t  This bolt is used at the factory to apply a pre-determined quantity of a specific grease to the thread of the drive plate. This quantity of grease is sufficient for once-only screwing of the drive plate onto the air conditioner compressor shaft. After unscrewing, drive plates are therefore not to be re-used.

Detaching –  Remove poly V-belt → Rep. gr.13. –  Remove the cap -A-. –  Use a commercially available 7 mm Allen key to support the drive shaft of the air conditioner compressor -B-. –  Turn the drive plate -C- with the pulley -E- in arrow direction--. –  Detach the drive plate.   Note t  The torque for driving the air conditioner compressor is applied to the air conditioner compressor shaft by way of the bolted joint of the drive plate. t  If in the course of air conditioner compressor operation the drive plate has become so firmly attached to the air conditioner compressor shaft that it can no longer be unfastened (the 7 mm hexagon can no longer transmit the necessary torque), the air conditioner compressor must be replaced.

–  Remove the circlip -A-. –  Detach the pulley -B-. Installing l  Tightening torque → Anchor Installation is carried out in the reverse order. When installing, note the following:   Note Replace the circlip. –  Clean the air conditioner compressor drive shaft before fitting the pulley. –  Attach the pulley to the air conditioner compressor drive shaft. l  without having to exert force. –  Insert the circlip -A- in the correct position. l  Fit with the bevelled side -C- facing away from the air conditioner compressor - flat side towards air conditioner compressor. –  Clean the thread of the air conditioner compressor drive shaft before screwing on the drive plate.   Note Thread of new drive plate has been lubricated at factory with a pre-determined amount of a specific grease.

–  Insert the rubber elements -D- in the pulley -B- as shown and moisten with a small quantity of tyre assembly paste or soap solution for example to provide lubrication. –  Insert the drive plate -C- in the rubber elements until these make contact with the drive shaft -B- of the air conditioner compressor. –  Press the rubber element of the drive plate into the pulley -E- until the drive plate makes contact with the thread of the air conditioner compressor drive shaft. –  Whilst providing support with an Allen key, screw the drive plate with the pulley onto the air conditioner compressor drive shaft by turning -in the direction opposite to the arrow-. –  Install poly V-belt → Rep. gr.13. Assembly overview of „Sanden“ („Delphi“) air conditioner compressor pulleys   Note t  If the pulley overload safeguard has been tripped, check the freedom of movement of the air conditioner compressor before replacing the pulley. Replace the entire air conditioner compressor if it is stiff. t  The air conditioner compressor can be detached from the bracket at the engine and re-attached without opening up the refrigerant lines. t  Currently, the pulley of the „Delphi“ air conditioner compressor is identical to the pulley of the „Sanden“ compressor (version „2“). The only difference is that the drive plate is attached to the air conditioner compressor shaft with a self-locking bolt → Item.

Version „1“ pulley

1 -	Conical hexagon bolt

q

25 Nm

–	Hold pulley using a commercially available strap wrench (fabric strap) when loosening or tightening hexagon nut

–	Use a thread cutter for example to remove the locking fluid applied to the thread of the nut on screwing in. Otherwise there is a danger of the drive shaft shearing off on next removal.

–	Use a wire brush to clean the thread of the air conditioner compressor drive shaft.

–	Apply locking fluid when fitting the nut. Locking fluid; refer to → Electronic parts catalogue

2 -

Bolt.

q

4.5 Nm

–	To slacken and tighten bolts, hold pulley in position with a commercially available strap wrench (with fabric strap).

–	Threaded holes which take self-locking bolts or bolts coated with locking fluid must be cleaned (using a tap or similar). Otherwise there is a danger of the bolts shearing off the next time they are removed.

–	Clean thread of bolts from remnants of locking fluid using wire brush. Then apply locking fluid and fit bolts. Locking fluid; refer to → Electronic parts catalogue

3 -	Drive plate

q	With overload protection device; triggered if torque is too great (e.g. if air conditioner compressor cannot rotate freely) causing pulley to free-wheel without driving air conditioner compressor

q	With rubber element for decoupling the pulley from the air conditioner compressor drive shaft, the rubber element damps vibration and noise

4 -

Plate

5 -

Circlip

q

Replace

q	Fit in correct position with the bevelled side -A- facing away from the air conditioner compressor - flat side facing air conditioner compressor

6 -

Pulley

7 -	Air conditioning compressor

q	Clean the air conditioner compressor drive shaft before fitting the pulley

Version „2“ pulley

1 -	Conical hexagon bolt

q

25 Nm

A plastic cap is additionally fitted to protect the thread of the air conditioner compressor drive shaft (this cap is not shown in the illustration).

–	To slacken and tighten bolts, hold pulley in position with a commercially available strap wrench (with fabric strap).

–	Threaded holes which take self-locking bolts or bolts coated with locking fluid must be cleaned (using a tap or similar). Otherwise there is a danger of the bolts shearing off the next time they are removed.

–	Clean thread of bolts from remnants of locking fluid using wire brush. Then apply locking fluid and fit bolts. Locking fluid; refer to → Electronic parts catalogue

2 -

Bolt.

q

12 Nm

–	To slacken and tighten bolts, hold pulley in position with a commercially available strap wrench (with fabric strap).

–	Threaded holes which take self-locking bolts or bolts coated with locking fluid must be cleaned (using a tap or similar). Otherwise there is a danger of the bolts shearing off the next time they are removed.

–	Clean thread of bolts from remnants of locking fluid using wire brush. Then apply locking fluid and fit bolts. Locking fluid; refer to → Electronic parts catalogue

3 -	Drive plate

q	With overload safeguard (attachment of spring elements); 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 facing air conditioner compressor

5 -

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.

t	Depending on the version, the threaded plates may also be linked by way of a ring.

t

Air conditioner compressors with a smaller displacement are gradually being introduced for vehicles for „cold countries“ (e.g. in Central and Northern Europe); the pulley for these air conditioner compressors differ slightly from the version in the illustration (e.g., the rubber elements -B- are not installed as vibration dampers) → Electronic spare parts catalogue.

6 -	Air conditioning compressor

q	Clean the air conditioner compressor drive shaft before fitting the pulley

Air conditioner compressor „Sanden“ („Delphi“) Currently the pulley cannot be renewed separately on air conditioner compressors manufactured by „Delphi“. In the event of problems, the entire air conditioner compressor is to be replaced. –  Replacing air conditioner compressor → Chapter.   Note Currently, the pulley of the „Delphi“ air conditioner compressor is identical to the pulley of the „Sanden“ compressor (version „2“). The only difference is that the drive plate is attached to the air conditioner compressor shaft with a self-locking bolt → Item. Assembly overview of „Zexel“„Valeo“ air conditioner compressor pulleys

t	Observe notes on removing pulley for „Denso“ air conditioner compressor (version „1“); these also apply to this air conditioner compressor → Anchor.

t	Perform same preparatory work (e.g. detaching pulley) as described for „Denso“ air conditioner compressor (version „1“) → Anchor.

t	On air conditioner compressors with part number 1K0 820 803 from index „N“ onwards, the splines of the drive plate are bonded to the splines of the compressor shaft. For procedure for removing drive plate, refer to → Anchor.

t

On air conditioner compressors with part number 1K0 820 803 up to index „L“, the splines of the drive plate are not bonded to the splines of the compressor shaft. With these air conditioner compressors, the splines of the drive plate may become worn and the compressor may no longer be driven → Anchor. In this case, check that the air conditioner compressor can move freely, and if necessary renew the drive plate (use repair set 1K0 898 814) → Electronic parts catalogue.

t	The logo of the compressor manufacturer „Zexel“ attached to the air conditioner compressor was modified from „Zexel“ to „Valeo“ from year of production 2006 onwards (change in manufacturer's name).

1 -

Bolt.

q

Replace

q	Hold pulley using a commercially available strap wrench (fabric strap) when loosening or tightening bolt

q	Clean off residual locking fluid from thread of air conditioner compressor shaft (and if necessary of bolt) before installing.

q	Apply locking fluid (e.g. D 000 600 A2) when fitting bolt → Electronic parts catalogue

q	Tightening torque: 17 Nm

2 -

Bolt.

q	Hold pulley using a commercially available strap wrench (fabric strap) when loosening or tightening bolt

q	Clean off residual locking fluid from thread of air conditioner compressor pulley (and if necessary of bolt) before installing.

q	Apply locking fluid (e.g. D 000 600 A2) when fitting bolt → Electronic parts catalogue

q	Tightening torque: 7 Nm

3 -	Drive plate

q	With overload protection device; triggered if torque is too great (e.g. if air conditioner compressor cannot rotate freely) causing pulley to free-wheel without driving air conditioner compressor

q	With rubber element for decoupling pulley from drive shaft of air conditioner compressor and for dampening vibrations and noise

q	On air conditioner compressors with part number 1K0 820 803 from index „N“ onwards, the splines of the drive plate are bonded to the splines of the compressor shaft. For procedure for removing drive plate, refer to → Anchor.

q	On air conditioner compressors with part number 1K0 820 803 up to index „L“, the splines of the drive plate are not bonded to the splines of the compressor shaft. With these air conditioner compressors, the splines of the drive plate may become worn and the compressor may no longer be driven.

If the drive plate has already been renewed as part of the service work and the new drive plate was bonded on using sealant D 154 102 A1, it may be so firmly attached to the compressor shaft that it can no longer be pressed off → Anchor. In this case the air conditioner compressor must be renewed as a complete unit.

4 -

Circlip

q

Replace

q	Do not reverse when installing; chamfer -A- faces away from air conditioning compressor (flat side towards air conditioner compressor)

q	When fitting circlip, take care not to bend it open more than necessary.

5 -

Pulley

q	Air conditioner compressor flange; clean before pushing on pulley

6 -	Air conditioning compressor

q	Different versions may be fitted, depending on type of engine and country-specific version of vehicle → Electronic parts catalogue

q	Air conditioner compressor flange; clean before pushing on pulley

Installation and removal of the „Zexel“„Valeo“ air conditioner compressor pulleys   Note t  Observe notes on removing pulley for „Denso“ air conditioner compressor (version „1“); these also apply to this air conditioner compressor → Anchor. t  Perform same preparatory work such as when detaching the pulley as described for „Denso“ air conditioner compressor version „1“ → Anchor. t  The logo of the compressor manufacturer „Zexel“ attached to the air conditioner compressor was modified from „Zexel“ to „Valeo“ from year of production 2006 onwards (change in manufacturer's name). Removing drive plate   Note t  On air conditioner compressors with part number 1K0 820 803 from index „N“ onwards, the splines of the drive plate are bonded to the splines of the compressor shaft. t  On air conditioner compressors with part number 1K0 820 803 up to index „L“, the splines of the drive plate are not bonded to the splines of the compressor shaft. With these air conditioner compressors, the splines of the drive plate may become worn and the compressor may no longer be driven. In this case, check that the air conditioner compressor can move freely, and if necessary renew the drive plate (use repair set 1K0 898 814) → Electronic parts catalogue.

–  Hold pulley -A- in position with a commercially available strap wrench (with fabric strap) and loosen bolt -B-.   Note t  If overload protection device of drive plate -D- has been triggered, pulley just free-wheels without driving air conditioner compressor. Check that air conditioner compressor can move freely by turning bolt -B-. If it is stiff, renew compressor with pulley. If air conditioner compressor moves freely, remove bolts -C- and detach drive plate. Then hold drive plate hub in position with pliers to loosen bolt -B-.

t  If the pulley splines have become worn, the bolt -B- cannot be slackened off (the compressor shaft turns with the bolt). In this case, remove the bolts -C- and clamp the drive plate to the air conditioner compressor shaft with the washer -A- (flat side facing outwards), the packing plates -B- and the bolts -C- (contained in the repair set 1K0 898 814 → Electronic parts catalogue). –  Then remove bolt -D-. –  Remove washer -A- and detach drive plate -A-.   Note

t  If the drive plate -A- is bonded to the shaft of the air conditioner, insert three long bolts -C- through the holes of the drive plate -A- into the pulley -D- and then use a commercially available bolt -B- (bolt with M8 thread, flat at front, property class at least 10.9) to press off the drive plate -A-. When doing so, hold the pulley -D- in position using a commercially available strap wrench (with fabric strap). t  If the drive plate -A- has already been renewed as part of the service work and the new drive plate was bonded on using sealant D 154 102 A1, it may be so firmly attached to the compressor shaft that it can no longer be pressed off. In this case the air conditioner compressor must be renewed as a complete unit. –  If pulley is to be renewed, remove circlip and detach pulley → Anchor. –  Clean and check splines of shaft of air conditioner compressor. Renew air conditioner compressor if splines show signs of wear.   Caution Do not use compressed air when cleaning; blowing out could cause dirt particles to settle on the seal of the air conditioner compressor shaft and damage it. Attaching drive plate   Caution Do not use compressed air when cleaning; blowing out could cause dirt particles to settle on the seal of the air conditioner compressor shaft and damage it.

–  Use a commercially available cleaning solution to remove rust, abrasion, old adhesive and other particles from splines of air conditioner compressor shaft -B-, pulley -A- and splines of drive plate -C-. –  Using e.g. a thread cutter, remove old locking fluid from thread in shaft of air conditioner compressor -B- and the three threads in pulley -A-. –  Check splines of air conditioner compressor shaft -B-. Renew compressor if splines show signs of wear. –  Check splines of drive plate -C- and renew drive plate if splines show signs of wear. –  If applicable, install the pulley and the corresponding circlip. –  Lubricate splines of air conditioner compressor shaft -B- and drive plate -C- with sealant „D 154 102 A1“ → Electronic parts catalogue.   Note t  Apply the sealant sparingly and make sure it does not come into contact with the seal of the air conditioner compressor shaft -B- (in the compressor). t  The sealant is also an adhesive. After it has dried, the drive plate can no longer be detached.

t  The sealant hardens within a certain period, so the drive plate must be installed within 5 minutes after applying the sealant to the splines. Before this time exceeds, the other screws -C- and -B- have to be tightened to the specified tightening torque → Anchor. –  Re-install remaining components in reverse order of removal. –  Wait one hour (after fitting the drive plate) before starting the engine.   Note It takes roughly one hour for the sealant to become rigid enough.