Compressor Belt Pulley/Drive Unit, Replacing (Compressor Without A/C Clutch)
Compressor Belt Pulley/Drive Unit, Replacing (Compressor Without A/C Clutch)
Belt pulley, replacing
Notes:
- Different versions of the pulley are installed, depending on compressor type and engine version.
- Pulley, removing from compressor and installing.
1. Bolt
- Replace
- Tightening torque 20 Nm
2. Drive plate
- Different versions
- Triggers with torque too high (e.g. compressor produces friction)
3. Snap ring
- Replace
- Install on proper side (level side to compressor)
4. Belt pulley
- Rubber element of pulley triggers when torque is too high (e.g. compressor produoes friction) and pulley runs freely without driving the compressor.
- Different versions
Note: Under certain conditions (e.g. rough engine idle), rubber element of pulley can disengage without a maffunction existing at compressor or in refrigerant circuit.
5. Compressor
- Different versions are installed depending on engine version and country version of vehicle.
- Clean compressor flange before sliding on pulley.
Pulley, Removing From Compressor And Installing
Notes:
- If overload protection of pulley triggers, check compressor for ease of motion before replacing the pulley. If compressor creates friction, replace it completely.
- To remove pulley, it depends on engine version if it is necessary to remove compressor from engine.
- The compressor can be removed and installed from the bracket without opening the refrigerant lines.
- Mark direction of rotation of ribbed belt using chalk or felt-tip marker before removing. Reversing the direction of rotation of a run-in belt can destroy the belt.
- Different compressors are installed, depending on engine and country version (installed on right or left at engine, 6-cyl. gasoline or diesel engine, cold or hot country).
- Remove noise insulation.
- Bring the lock carrier into service position.
- Release tension on ribbed belt and remove it.
- Remove bolt -A- (tightening torque 20 Nm).
Notes:
- If pulley cannot be ~moved with oompressor installed, remove compressor from engine.
- To loosen and tighten bolt -A-, counterhold it at drive plate -B- using a commercially available pin wrench -C- (pin diameter 50 mm).
- Bolt -A- is to be replaced (because of locking compound).
- Carefully and uniformly pry off drive plate -A- using 2 screwdrivers -B-.
Notes:
- Make sure that the collar for pulley -C-is not damaged when prying off drive plate -A-.
- There are different versions of pulley -C- and drive plate -A-, therefore note the exact assignment.
- Remove securing ring -A-.
- Remove pulley -B-.
Notes:
- Replace securing ring -A-.
- When installing securing ring -A-, note that it cannot be bent open more than is necessary for installation.
- Insert securing ring -A- on pmper side, the side with beveled insertion edge -C- faces away from compressor (install flat side facing compressor).
- Ensure pmper seating of securing ring in groove an compressor flange.
- Clean compressor flange before fitting the pulley on, pulley must be able to be fitted easily. (fitting must be possible without much force).
Compressor drive unit, checking, replacing
Notes: If overload protection of drive plate has triggered, check compressor for ease of motion before replacing the drive unit. If compressor creates friction, replace it completely.
1. Compressor drive unit
- Check, drive shaft must sit free of play in engine drive wheel splines with threads tightened.
- Tightening torque 60 Nm
- Lubricate splines of engine drive wheel using G000100 clutch splining grease
2. Socket-head bolt
- Tightening torque 8 Nm
3. Drive plate
- With overload protection, disengages at a too high torque (e.g. when compressor does not move freely) and drive shaft moves freely without driving compressor.
- Checking and adjusting run out
4. Drive plate
- Threaded to drive shaft of compressor
- Tightening torque 20 Nm
5. Rubber element
- Disengages drive unit, damps vibrations and noise.
- When installing, coat rubber element lightly e.g. using tire mounting paste (as lubricant).
6. Spacing disc
- Dimensions: 17.5 x 10 x 3 mm
7. Securing ring
- Replace
- Install on proper side (level side to compressor)
8. Drive plate
- With roller bearing.
- Clean compressor flange before sliding on drive plate.
9. Compressor
- Different versions may be installed, depending on engine version and country version of vehicle.
Compressor drive shaft, loosening and tightening
- Support engine using 10-222A engine support bridge (so that left engine mount can be removed).
- Remove oil dipstick from engine
- Remove noise insulation
- Remove left engine mount completely (engine console1 engine mount and engine support)
Drive shaft, loosening
- Hold compressor drive shaft -A- in place using open-end wrench and turn compressor drive unit -B- in direction of arrow -C-.
Notes:
- Drive shaft -A- must not be turned.
- Drive shaft -A- can be slid into drive wheel through the boot -E- after loosening threaded connection.
- After installing drive shaft -A-, check installation position of boot -E-.
Drive shaft, tightening
- Hold compressor drive shaft -A- in plaoe using an open-end wrench and turn compressor drive unit -B-in direction of arrow -D- (tightening torque 60 Nm).
- After tightening compressor drive shaft, check installation position of boot -E-
Compressor Drive Shaft, Removing And Installing
Removing
- Remove compressor
- Remove boot -A-
- Remove drive shaft -B- fmm splines of drive pinion-C-
Installing
Installation is the reverse of removal, noting the following:
- Check drive shaft -B-, splines must show no trades of wear and it must sit free of play in splines of drive wheel -C-.
- Coat splines of drive shaft -B- using clutch splining grease G000100 before installing.
- Insert drive shaft -B- before installing compressor and slide it into drive wheel -C- up to stop.
- After installing compressor, check installation position of boot -A-.
Drive plate with overload protection, removing and installing
- Remove compressor
Removing
- Remove bolts -A-
Note: Use a commercially available strap wrench (with webbed strap) to counterhold on drive plate -C-.
Installing
- Position drive plate with overload protection -B- onto drive plate -C-.
- Insert bolts -A- and tighten by hand.
- Check run-out of drive plate -B-.
- Tighten bolts -A- (tightening torque 8 Nm).
- Check run-out of drive plate -B- once more.
Run-out of drive plate with overload protection, checking and adjusting
- Remove compressor.
- Clean flange at drive plate -A-
- Secure a dial gauge -B- to compressor using a dial gauge holder -C- (e.g. 387 special tool holder).
- Set dial gauge indenter of dial indicator -D- on flange of drive plate -A- with a pre-tension of approx. 1.0 mm.
- Turn compressor drive unit -E- several rotations.
Specified value: Run-out deviation is less than 0.21 mm (run-out of dial indicator, difference between smallest and largest measured value 0.2 mm maximum)
- If run-out deviation is greater than 0.2 mm, remove bolts on drive plate and adjust drive plate anew.
Drive plate to compressor, removing and installing
- Remove drive plate with overload protection.
Removing
- Loosen drive plate -C- by turning in direction of arrow -D- using a commercially available strap wrench (with webbed strap), counter hold compressor shaft -A- using a counterholder tool -B- (e.g. socket wrench from T10001/10 socket wrench set or 3079 counter holder) on compressor shaft -A-.
Installing
- When installing1 coat rubber element lightly e.g. using tire mounting paste (as lubricant).
- Insert rubber element -B- in drive plate -A- according to illustration.
- Insert drive plate -A- with rubber elements -B- onto drive plate -C- according to illustration until it makes contact with compressor shaft.
- Thread drive plate -C-on to compressor shaft -A- by turning in direction of arrow -E-.
- Tighten drive plate -C- by turning in direction of arrow -E- to 20 Nm using a commercially available strap wrench (with webbed strap)1 counter hold compressor shaft -A- using a counterholder tool -B- (e.g. socket wrench from T10001/10 socket wrench set) on compressor shaft -A-.
Drive plate with roller bearing, removing and installing
- Remove drive plate from compressor shaft.
- Remove securing ring -A-.
- Remove drive plate -B-.
Notes:
- Replace securing ring -A-.
- Clean compressor flange before sliding on drive plate.
- When installing securing ring -A-, note that it cannot be bent open more than is necessary for installation.
- Insert securing ring -A-on proper side, the side with beveled insertion edge -C- faces away from compressor (install flat side facing compressor).