Volkswagen Golf Service & Repair Manual: Removing and installing Denso belt pulley

Volkswagen Golf Service & Repair Manual / Heating, air conditioning / Air conditioner / Air conditioner compressor / Removing and installing Denso belt pulley

Note

The pulley is sensitive to impact and should therefore be treated with extreme care.

If the belt pulley overload protection has deployed, check freedom of movement of air conditioner compressor before renewing belt pulley. If air conditioner compressor cannot rotate freely it must be renewed.

If the drive plate overload protection device has been triggered, the pulley can rotate with the outer section of the drive plate without the air conditioner compressor shaft and the hexagon flats attached to the drive plate (inner section of drive plate) also rotating.

Special tools and workshop equipment required

Commercially available oil filter strap wrench

Removing

–	Remove poly V-belt → Rep. gr.13.

–	Pull off sealing cap -1-.

–	Counterhold pulley with oil filter strap wrench and remove bolts -arrows-.

Removing and installing Denso belt pulley

–	Remove nut -2-; to do so counterhold drive shaft -1- for air conditioner compressor.

–	Detach drive plate -3- with nut.

Note

The torque for driving the air conditioner compressor is applied to the air conditioner compressor shaft via the threaded connection of the drive plate.

If the drive plate has become so firmly screwed onto the air conditioner compressor shaft that it can no longer be loosened (the 7 mm hexagon flats can no longer transmit the necessary torque), the air conditioner compressor must be renewed.

Removing and installing Denso belt pulley

–	Detach circlip -2-.

–	Detach pulley -1-.

Installing

Installation is carried out in the reverse order. When installing, note the following:

Note

Renew circlip.

–	Clean drive shaft of air conditioner compressor before fitting the belt pulley.

–	Fit belt pulley onto drive shaft of air conditioner compressor.

The belt pulley must be fitted without excessive force being applied.

–	Insert circlip in correct position.

Flat side faces air conditioner compressor

–	Clean thread of air conditioner compressor drive shaft before bolting on drive plate.

Note

The thread of the new drive plate is greased with a specified amount of a certain grease by the manufacturer.

Specified torque

→ Chapter „Assembly overview - belt pulley, Denso air conditioner compressor“

Removing and installing Denso belt pulley

Checking high-pressure safety valve on air conditioner compressor

Checking Function: protects refrigerant circuit against excessive pressures. – Observe safety precautions ...

Removing and installing Sanden belt pulley

Note The pulley is sensitive to impact and should therefore be treated with extreme care. If the belt pulley overload prot ...

Other materials:

Overview of fitting locations - front keyless entry system, RHD vehicles
1 - Front passenger door exterior handle With front passenger door exterior handle contact sensor -G416-. Removing and installing → Chapter With front passenger side aerial for entry and start system -R135-. Removing ...

Assembly overview - bumper cover
Note Minor differences may be encountered in respect of bumper cover, depending on vehicle model. 1 - Bumper cover Material PP/EPDM Removing and installing → Chapter 2 - Guide bracket Lef ...

Assembly overview - backrest release mechanism and entry assistance
1 - Connecting Bowden cable Between backrest release mechanism and mounting bracket for backrest release mechanism Removing and installing → Chapter 2 - Trim for backrest release mechanism Removing and installing ...