VW Golf manuals

Volkswagen Golf Service & Repair Manual: 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

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