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Pulley: Replacing (compressor make ?Sanden?) > < Pulley: Replacing (compressor make ?Zexel?)

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Removing and fitting the pulley (compressor brand „Zexel“)
Removing and fitting the pulley (compressor brand „Zexel“)
  Note
t  Follow the instructions for the removal of the pulley in the compressor make „Denso“, version „1“; these instructions are also valid for this compressor → Chapter.
t  Carry out preparation work in the same way as for the removal of the pulley in the compressor make „Denso“, version „1“ → Anchor.
Removing and installing drive plate
  Note
t  Compressors with the part number 1K0 820 803 from index „N“ have the disk grooves on the drive plate fastened to the grooves on the compressor shaft.
t  Compressors with the part number 1K0 820 803 to index „L“ have the disk grooves on the drive plate free from the grooves on the compressor shaft. In these compressors it is possible that the drive plate grooves wear down and can no longer drive the compressor. In this case, check whether the compressor moves easily, and replace the drive plate if necessary (using the repair kit 1 K0 898 814) → Parts catalogue
   
–  Hold the pulley -A- using a strap wrench (with a braided strap) and release the bolt -B-
  Note
t  If the protection against overloading the drive plate is active -D-, the pulley turns freely without driving the compressor. Check ease of movement in the compressor by turning it by its bolt -B-; should movement be difficult, replace the compressor with the pulley. If the compressor does move easily, remove the bolts -C- and remove the drive plate. Then hold drive plate hub in position with pliers to loosen bolt -B-.
  A87-10246
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 tighten the drive plate with the disk -A- (flat side facing outwards), the washers -B- and the bolts -C- (included in the repair kit 1 K0 898 814 → Parts catalogue) on the compressor shaft
–  Then remove bolt -D-.
–  Remove washer -A- and detach drive plate -A-.
  Note
  A87-10247
t  If the drive plate -A- is fastened to the compressor shaft, fit three long bolts -C- through the orifices in the clutch plate -A- on the pulley -D- and separate the drive plate -A- with a normal bolt -B- (bolt with M8 thread, flat in front and with a resistance of min. 10.9). When doing so, hold the pulley -D- in position using a commercially available strap wrench (with fabric strap).
t  When the drive plate -A- has already been replaced once and has been pasted with sealing agent D 154 102 A1, it may occur that the plate connects itself with the compressor shaft in such a way that it will not be able to be separated. In this case the complete compressor must be replaced.
–  If the pulley must be replaced, release the circlip and remove the pulley
–  Clean the grooves of the compressor shaft and examine it; replace the compressor if there are signs of wear in the grooves
  Caution
Do not use compressed air for cleaning, as the dirt particles can reach the compressor shaft seal and damage it.
Installation
  Caution
Do not use compressed air for cleaning, as the dirt particles can reach the compressor shaft seal and damage it.
  A87-10248
–  Clean the grooves of the compressor shaft -B-, the pulley -A- and the grooves of the drive plate -C- with a normal cleaning product (eliminate the rust, worn particles, old adhesive and other material).
–  Clean the thread of the compressor shaft -B- and the three threads of the pulley -A- eliminating the leftover bolt fastening paste (e.g with a thread tapping bolt).
–  Clean the grooves of the compressor shaft -B-; replace the compressor if there are signs of wear in the grooves
–  Examine the grooves in the drive plate -C-; replace the drive plate if there are signs of wear in the grooves.
–  Fit the pulley and its circlip (if removed)
–  Apply sealant „D 154 102 A1“ on the grooves of the compressor shaft -B- and the grooves of the drive plate -C- → Parts catalogue
  Note
t  Apply sealant in moderation, taking care that it does not reach the compressor shaft seal -B- (in the compressor interior).
t  The sealant is also adhesive; once dry, the drive plate cannot be detached.
  A87-10249
t  The sealant hardens out after a certain period. Therefore, the drive plate must be mounted to the connection within 5 minutes after applying the sealing agent and the bolts -C- and -B- must also be tightened to the specified tightening torque within this time period.
–  Re-install remaining components in reverse order of removal.
–  Wait one hour (after fitting the drive plate) before starting the engine.
  Note
The sealant requires an hour approx to reach the required resistance.
  A87-10246

Pulley: Replacing (compressor make ?Sanden?) > < Pulley: Replacing (compressor make ?Zexel?)