Pulley, Detaching/Re-Attaching From Compressor

Pulley, Detaching/re-attaching From Compressor

NOTE:
- At this time, only 8 cyl. gasoline engines are intended for the USA, information for other engine versions are to be disregarded in the USA until the gradual introduction of this engine type.
- If pulley overload safeguard has been tripped, check freedom of movement of compressor before replacing pulley. Replace entire compressor if it is stiff.
- Operation of pulley overload safeguard is described, for example, in Self Study Program Audi A2 Technology Number 240.
- Depending on engine version, detaching of pulley may involve separating compressor from engine.
- Compressor can be detached from holder and re-attached without opening up refrigerant pipes.
- Before removing, mark direction of operation of ribbed belt with chalk or felt-tipped pen. Running a used belt in the opposite direction could destroy it.
- Type of engine and country version govern compressor design (6, 8 or 12-cyl. engine; gasoline).

- Remove noise insulation.
- Move lock carrier to service position.
- Slacken off and detach ribbed belt.







- Screw out bolt -A- (tightening torque: 20 Nm).

NOTE:
- When slackening off and tightening bolt -A-, provide support with a commercially available pin wrench -C- (pin diameter 5.0 mm) at drive plate -B-.
- Bolt -A- is to be replaced (on account of locking fluid).
- Should it not be possible to detach pulley with compressor in position, disassemble compressor from engine.







- Use 2 screwdrivers -B- to carefully and evenly pry off drive plate -A-.

NOTE:
- When prising off drive plate -A-, take care not to damage collar of pulley -C-.
- There are different types of pulley -C- and drive plate -A-. Attention must therefore be paid to precise assignment.







- Remove circlip -A-.
- Detach pulley -B-.

NOTE:
- Replace circlip -A-.
- On fitting circlip -A-, take care not to bend it open more than necessary.







- Insert circlip -A- in correct position. Side with bevel -C- faces away from compressor (flat side is to be fitted facing compressor).
- Make sure circlip is properly positioned in groove at compressor flange.
- Clean compressor flange before fitting pulley. Pulley must be easy to fit (without having to exert force).