Replacing air conditioner compressor pulley (“Zexel / Valeo” make) — AUDI

Replacing air conditioner compressor pulley (
“Zexel / Valeo”
make)
Note
Heed the notes on removal of the pulley for the
“Denso”
air conditioner compressor of type
“1”
. These also apply to this compressor
Chapter
.
Perform the preparatory work as described for detaching the pulley with the
“Denso”
air conditioner compressor of type
“1”
Chapter
.
On air conditioner compressors with part number 1K0 820 803 as of index
“N”
, the splines of the drive plate are bonded to the splines of the compressor shaft. For removing the drive plate, refer to
Chapter
.
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 such air conditioner compressors, the drive plate splines may become worn and the compressor may no longer be driven
Chapter
. In this case, check the freedom of movement of the air conditioner compressor and replace the drive plate if necessary using the repair set 1K0 898 814
Electronic parts catalogue
.
The logo of the compressor manufacturer
“Zexel”
affixed to the air conditioner compressor was switched as of year of production 2006 (when the manufacturer's name changed) from
“Zexel”
to the new name
“Valeo”
.
Bolt
Replace
To slacken off and tighten the bolt, hold the pulley in position with a commercially available strap wrench (with fabric strap).
Before screwing in, remove old locking fluid from the thread in the air conditioner compressor shaft (and from the bolt if applicable).
Apply locking fluid when fitting the bolt (e.g. D 000 600 A2)
Electronic parts catalogue
.
Tightening torque 17 Nm
Bolt
To slacken off and tighten the bolt, hold the pulley in position with a commercially available strap wrench (with fabric strap).
Before screwing in, remove old locking fluid from the thread in the air conditioner compressor pulley (and from the bolt if applicable).
Apply locking fluid when fitting the bolt (e.g. D 000 600 A2)
Electronic parts catalogue
.
Tightening torque 7 Nm
Drive plate
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.
With rubber element for decoupling the pulley from the air conditioner compressor drive shaft and for damping vibration and noise.
On air conditioner compressors with part number 1K0 820 803 as of index
“N”
, the splines of the drive plate are bonded to the splines of the compressor shaft. For removing the drive plate, refer to
Chapter
.
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 such air conditioner compressors, the drive plate splines may become worn and the compressor may no longer be driven.
Note
If the drive plate has already been replaced as part of service work and bonded on using the sealant D 154 102 A1, it may be so firmly attached to the air conditioner compressor shaft that it can no longer be pressed off
Chapter
. In this case the entire compressor must be replaced.
Circlip
Replace
Fit in correct position with the bevelled side
A
facing away from the air conditioner compressor (flat side towards compressor).
On fitting the circlip, take care not to bend it open more than necessary.
Pulley
Clean the air conditioner compressor flange before fitting the pulley.
Air conditioner compressor
Different models may be fitted depending on the engine version and country version of the vehicle
Electronic parts catalogue
.
Clean the air conditioner compressor flange before fitting the pulley.