Belt Pulley, Zexel/Valeo
Belt Pulley, Zexel/Valeo
• Observe notes for removing belt pulley for compressor manufactured by Denso version 1, these also apply to this A/C compressor. Refer to=> [ Belt Pulley, Denso Version 1 ] Belt Pulley, Denso Version 1.
• Perform any preliminary work as described for removing belt pulley on compressor manufactured by Denso version 1. Refer to => [ Preparation ] Belt Pulley, Denso Version 1.
• Beginning the production year 2006, the name of the Zexel A/C compressor was changed from Zexel to Valeo.
Removing Drive Plate
• On A/C compressors with part number 1K0 820 803 as of index N, the drive plate splines are bonded to A/C compressor shaft splines.
• On A/C compressors with part number 1K0 820 803 up to index L, the drive plate splines are not bonded to A/C compressor shaft splines, removing drive plate. On these A/C compressors it may be possible that the drive plate splines are worn off and the A/C compressor is no longer driven. In this case, check the A/C compressor for freedom of movement and if necessary replace drive plate, use the repair set 1K0 898 814. Refer to Electronic Parts Catalog (ETKA).
- Hold belt pulley - A - firmly in place using a conventional band wrench (with webbed band) and loosen bolt - B -.
• If drive plate overload protection - D - has triggered, the belt pulley turns freely without driving the A/C compressor. Check the A/C compressor for freedom of movement by turning at bolt - B -, replace a A/C compressor with belt pulley that turns with resistance. If compressor moves freely, in this case remove bolts - C - and remove drive plate. Then hold drive plate hub firmly in place using pliers to loosen bolt - B -.
• If belt pulley splines have been worn away, bolt - B - cannot be loosened (compressor turns along with the bolt). In this case, remove the bolts - C - and tension drive plate with washer - A - (flat side faces outward), washers - B - and bolts - C - (contained in repair set 1K0 898 814, refer to Electronic Parts Catalog (ETKA)) on to A/C compressor shaft.
- Then remove bolt - D -.
- Remove washer - A - and remove drive plate - A -.
• If drive plate - A - has bonded to A/C compressor shaft, install three long bolts - C - in belt pulley - D - through holes of drive plate - A - and then press off drive plate - A - with a convention bolt - B - (bolt with an M8 thread that is flat in the front and has a minimum rigidity class of 10.9). While doing this, hold belt pulley - D - firmly in place using a conventional band wrench (with webbed band).
• If drive plate - A - has already been replaced once in customer service and was bonded at that time using sealing compound D 154 102 A1, it may be joined so securely to the A/C compressor shaft that it can no longer be pressed off, in this case the entire A/C compressor must be replaced.
- In the event the belt pulley is to be replaced, remove circlip and remove belt pulley. Refer to=> [ A/C Compressor Belt Pulley, Zexel/Valeo Overview ] A/C Compressor Belt Pulley, Zexel/Valeo Overview.
Do not use pressurized air when cleaning, dirt particles may impinge on the compressor shaft seal and damage it when blowing out contaminants.
- Clean and check the splines on the A/C compressor shaft. If the splines are showing wear, replace the A/C compressor.
Installing Drive Plate
Do not use pressurized air when cleaning, dirt particles may impinge on the compressor shaft seal and damage it when blowing out contaminants.
- Clean the splines on the A/C compressor shaft - B -, the belt pulley - A - and the splines on the drive plate - C - (remove any rust, abraded material, old sealant and other particles).
- Clean thread on A/C compressor shaft - B - and the three threads in belt pulley - A - of old bolt locking compound (for example, using a thread tap).
- Check the splines on the A/C compressor shaft - B -. If the splines are showing wear, then replace the A/C compressor.
- Check the splines on the drive plate - C -. Replace the drive plate if the splines are showing wear.
- If necessary, install belt pulley and the corresponding circlip. Refer to=> [ A/C Compressor Belt Pulley, Zexel/Valeo Overview ] A/C Compressor Belt Pulley, Zexel/Valeo Overview.
- Coat splines on A/C compressor shaft - B - and drive plate - C - with sealant "D 154 102 A1". Refer to Electronic Parts Catalog.
• Apply sealant sparingly all around, making sure that no sealant reaches the A/C compressor shaft seal - B - (in the A/C compressor).
• The sealant is also an adhesive, after hardening the drive plate can no longer be removed.
• The sealant hardens within a certain time period, therefore mount the drive plate within 5 minutes after coating splines with sealant and tighten bolts - C - and - B - to the specified torque. Refer to => [ A/C Compressor Belt Pulley, Zexel/Valeo Overview ] A/C Compressor Belt Pulley, Zexel/Valeo Overview also within this time.
- Install the remaining removed components again in reverse order.
- Wait one hour (from mounting the drive plate) before starting the engine.
• Sealant requires approximately one hour to attain the necessary rigidity.