Belt Pulley, Denso Version 2

Belt Pulley, Denso Version 2

• Observe notes for removing belt pulley of version 1, these also apply for version 2. Refer to => [ Belt Pulley, Denso Version 1 ] Belt Pulley, Denso Version 1.

• Perform any necessary preliminary work to remove version 1 belt pulley. Refer to => [ Preparation ] Belt Pulley, Denso Version 1.

• Belt pulley is made of plastic and is sensitive to impact, therefore handle it with especial care.

• If the drive plate overload protection - C - has been triggered, then the drive plate can be pried off belt pulley - D - after removing circlip - A -






• A plastic disc - B - may be installed on drive plate of belt pulley - A - to optimize noise reduction. Refer to Electronic Parts Catalog (ETKA). The plastic disc - B - can reduce a clapping (castanet-like) noise which occurs especially at belt pulley in vehicles with Diesel engine in A/C system operating mode "Econ" (A/C compressor activation switched off); the noise is almost inaudible with A/C system operating at full output.






• Depending on the version of the A/C control head, it is possible to identify when "Econ"is on. Either the indicator lamp inside the ECON button will be on and the indicator lamp in the AC button will be off.

Removing

- Remove the plastic disc - B - from belt pulley - A - (if installed).






- Using a small screwdriver or needle-nose pliers, carefully remove the circlip - A - (which might have rubber disc vulcanized on to it); take extreme care not to damage belt pulley when doing this.






- Hold A/C compressor input shaft - B - firmly in place using a standard Allen wrench or a socket wrench from the shock absorber set (T10001) (depending on version of A/C compressor) and rotate drive plate - C - along with belt pulley - D - in direction of arrow - E - (tightening specification: 35 Nm).

- Remove drive plate - C -.

- Remove circlip - A -.






- Remove pulley - B -.

Installing

• Replace circlip - A -.

• Clean the A/C compressor flange before sliding on the belt pulley.

• When installing circlip - A -, note that it cannot be bent open more than is necessary for installation.

- Install belt pulley - B -.

- Insert circlip - A - on correct side, the side with beveled insertion edge - C - faces away from A/C compressor (install flat side facing compressor).

- Insert rubber element - D - in belt pulley - B - according to illustration.

- When installing drive plate, coat rubber element - D - lightly e.g. with tire mounting paste or soap solution (as sliding compound).

- Insert the drive plate - C - far enough into rubber elements - D - (see upper illustration) until it contacts the A/C compressor shaft - B -.






- Install the drive plate - C - on the compressor shaft - B - by rotating it in the direction of the arrow - F -.

- Tighten drive plate - C - (via belt pulley - D -) to 35 Nm by rotating in direction of arrow - F - using a conventional band wrench (with webbed band). Hold the compressor shaft - B - firmly in place using a commercially available hex wrench or the socket wrench from the shock absorber set (T10001).

- Install circlip - A - (with rubber disc).

- Clean drive plate of belt pulley - A - and glue plastic disc - B - centered onto drive plate (only on A/C compressors without rubber ring on circlip).