Audi Q3: Belt Pulley, Removing and Installing, Valeo A/C Compressor

  Note

• On A/C compressors with part number 1K0 820 803 as of index "N", the drive plate splines are bonded to Air Conditioning (A/C) compressor shaft splines, removing drive plate. Refer to → Chapter "Belt Pulley, Removing and Installing, Valeo A/C Compressor".
• On A/C compressors with part number 1K0 820 803 up to index "L", the drive plate splines are not bonded to A/C compressor shaft splines, removing drive plate. On these A/C compressors it may be possible that the drive plate splines are worn off and the A/C compressor is no longer driven. Refer to → Chapter "Belt Pulley, Removing and Installing, Valeo A/C Compressor". In this case, check the A/C compressor for freedom of movement and if necessary replace drive plate, use the repair set 1K0 898 814 to do so. Refer to the Parts Catalog.
• If the drive plate overload protection -D- has triggered, the belt pulley turns freely without driving the A/C compressor.
• Check the A/C compressor for freedom of movement by turning at bolt -B-, replace a A/C compressor with belt pulley that turns with resistance.
• If compressor moves freely, in this case remove bolts -C- and remove drive plate. Then hold drive plate hub firmly in place using pliers to loosen bolt -B-.

Removing

- Remove the ribbed belt. Refer to → Engine Mechanical, Fuel Injection and Ignition; Rep. Gr.13; Cylinder Block, Belt Pulley Side; Ribbed Belt, Removing and Installing.

- To loosen the bolt -B- using a commercially available strap wrench (with cloth tape), hold the belt pulley -A- firmly.

  Note

If belt pulley splines have been worn away, the bolt -B- cannot be loosened (the A/C compressor shaft turns along with the bolt).

- For a belt pulley with worn out splines, remove the bolts -C-.

- Position the disc -A- - the flat side faces outward.

- Secure the drive plate with the disc -A- from the Repair Kit -1K0 898 814- on the A/C compressor shaft by mounting the washers -B- and tightening the bolts -C-.

- Remove the bolt -D-.

- Remove the washer and drive plate.

  Note

If the drive plate is bonded to the A/C compressor shaft, press off the belt pulley.

- Install the long bolts -C- through the holes on the drive plate -A- in the belt pulley -D-.

- Using a commercially available M8 bolt -B- (strength category at least 10.9), press the drive plate -A- off of the A/C compressor shaft, while counterholding the belt pulley -D- with a commercially available strap wrench (with cloth tape).

  Note

If the drive plate -A- has already been replaced once in customer service and was bonded at that time with sealant, it may be joined so securely to the A/C compressor shaft that it can no longer be pressed off. The entire A/C compressor must be replaced.

- Remove the circlip, refer to -item 4- and remove the belt pulley.

Installing

Installation is done is reverse order, observe the following:

- Check the input shaft splines -B- of the A/C compressor and the drive plate splines -C- for wear. Replace if necessary.

  Caution

Do not use pressurized air when cleaning, dirt particles may impinge on the compressor shaft seal and damage it when blowing out contaminants.

- Clean the input shaft splines -B- of the A/C compressor, the belt pulley -A- and the drive plate splines -C- with a commercially available cleaning solution so that they are free of rust, abrasion, old adhesive and other particles.

- The threaded bolt holes, into which the self-locking bolts or bolts with locking compound were installed, must be cleaned (for example with a thread tap). Otherwise, there is a danger that the bolts break off during assembly.

- Clean the thread of the bolts, which are screwed in with locking compound, with a wire brush.

- Mount the belt pulley on the A/C compressor input shaft and insert the circlip.

- Thinly apply sealant on the input shaft splines -B- of the A/C compressor and the drive plate splines -C-. For the sealant, refer to the Parts Catalog.

  Note

• Make sure that the sealant does not get onto the seal for the A/C compressor input shaft (in the A/C compressor).
• The sealant is also an adhesive, after hardening the drive plate can no longer be removed.
• After applying the sealant, the drive plate must be installed within five minutes and the bolts tightened to specification.

- Slide the drive plate onto the A/C compressor input shaft.

- Tighten the bolts -B and C- to the tightening specification.

  Caution

Risk of damaging the A/C compressor.

After assembling the drive plate, the engine may only be started after one hour, which is the time needed for the sealant to become rigid.

- Install the ribbed belt. Refer to → Engine Mechanical, Fuel Injection and Ignition; Rep. Gr.13; Cylinder Block, Belt Pulley Side; Ribbed Belt, Removing and Installing.

Belt Pulley, Removing and Installing, Delphi A/C Compressor

  Note

• The "Delphi" A/C compressor belt pulley cannot be removed separately. If there is a complaint, replace the entire A/C compressor. Refer to the Parts Catalog and → Chapter "A/C Compressor, Removing and Installing".
• The belt pulley on the "Delphi" A/C compressor currently is identical in construction to the belt pulley on the "Sanden" A/C compressor, version "2". However, the drive plate is secured with a self-locking bolt, refer to item -2- to the A/C compressor shaft.

- Replace the A/C compressor. Refer to → Chapter "A/C Compressor, Removing and Installing on Bracket".

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