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Replacing air conditioner compressor pulley ("Zexel / Valeo" make) > < Replacing air conditioner compressor pulley ("Denso" make, version "3")

A3 Mk2

Detaching pulley from air conditioner compressor/re-attaching („Denso“ make, version „3“)
Detaching pulley from air conditioner compressor/re-attaching („Denso“ make, 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  Perform the preparatory work as for pulley detachment → Chapter.
t  The pulley is made of plastic, is sensitive to impact and should therefore be treated with extreme 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 compressor shaft -B- and the hexagon -D- attached to the drive plate (inner section of drive plate -C-) also turning.
Detaching
  A87-10429
–  Remove the cap -A-.
–  Hold the air conditioner compressor drive shaft -B- with a commercially available hexagon socket wrench (7 mm) for example and turn the drive plate -C- with the pulley -E- in arrow direction -arrow-.
  Note
The torque for driving the air conditioner compressor is applied to the compressor shaft by way of the bolted joint of the drive plate -C-. If in the course of air conditioner compressor operation the drive plate -C- has become so firmly attached to the compressor shaft that it can no longer be unfastened (the 7 mm hexagon socket wrench -B- can no longer transmit the necessary torque), the air conditioner compressor must be replaced.
–  Detach the drive plate -C-.
  A87-10429
–  Remove the circlip -A-.
–  Detach the pulley -B-.
Attaching
  Note
Replace the circlip -A-.
Clean the air conditioner compressor flange before attaching the pulley -B-.
On fitting the circlip -A-, take care not to bend it open more than necessary.
–  Fit the pulley -B-.
–  Ensure correct insertion of the circlip -A-. The bevelled side -C- faces away from the air conditioner compressor (flat side faces compressor).
–  Clean the thread of the compressor shaft before attaching the drive plate.
  Note
The thread of the new drive plate is pre-greased at the factory with a pre-determined quantity of a specific grease.
–  For fitting the drive plate, moisten the rubber elements -D- slightly with tyre assembly paste or soap solution for example to provide lubrication.
–  Insert the rubber elements -D- in the pulley -B- as shown.
  A87-10430
–  Press the rubber element of the drive plate -C- into the pulley -E- until the drive plate -C- makes contact with the thread of the shaft of the air conditioner compressor -B-.
–  Screw the drive plate -C- onto the compressor shaft -B- by turning it in the direction opposite to the arrow -arrow-.
–  Hold the air conditioner compressor drive shaft -B- with a commercially available hexagon socket wrench (7 mm) for example and turn the drive plate -C- with the pulley -E- in the direction opposite to the arrow -arrow- (tightening torque 30 Nm).
  A87-10429

Replacing air conditioner compressor pulley ("Zexel / Valeo" make) > < Replacing air conditioner compressor pulley ("Denso" make, version "3")