Belt Pulley, Denso Version 1

Belt Pulley, Denso Version 1

• If overload protection of pulley triggers, check the A/C compressor for ease of motion before replacing the pulley. If the A/C compressor creates friction, replace it completely.

• The ribbed belt (version 1) overload protection is described in Self Study Program No. 240; Audi A2 Technical Information.

• To remove belt pulley, it depends on engine version if it is necessary to remove A/C compressor from engine. Refer to => [ Compressor, Removing From Bracket ] Compressor, Removing From Bracket.

• The A/C compressor can be removed and installed at the bracket on engine 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.

• There are different versions of the A/C compressor installed. This depends on the engine and the country. Refer to Electronic Parts Catalog (ETKA).

• Preparation.

• Belt pulley, removing and installing, refer to => [ A/C Compressor Belt Pulley, Denso Version 1 Overview ] A/C Compressor Belt Pulley, Denso Version 1 Overview.

Preparation

- Remove the noise insulation.

- Remove the noise insulation frame , if equipped (for example, currently on the Audi A3 Cabrio).

- Release tension on ribbed belt and remove it.

- Remove the A/C compressor from the engine, if necessary. Refer to=> [ Compressor, Removing From Bracket ] Compressor, Removing From Bracket.

Removing

- Remove bolt - A - (tightening specification: 20 Nm).






• To loosen and tighten bolt - A -, counterhold it at drive plate - B - using a commercially available pin wrench - C - (pin diameter 5.0 mm).

• Bolt - A - is to be replaced (because of locking compound).

• If the belt pulley cannot be removed with A/C compressor still installed, then remove the A/C compressor from the engine. Refer to => [ Compressor, Removing From Bracket ] Compressor, Removing From Bracket.

- Carefully and uniformly pry off drive plate - A - using 2 screwdrivers - B -.






• 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. Refer to Electronic Parts Catalog (ETKA).

- Remove circlip - A -.






- Remove pulley - B -.

Installing

• Replace circlip - A -.

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

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






• Ensure proper seating of circlip in groove on 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).