Hey guys -

I always hated how the AC compressor's pulley looked rusty and tired, didn't figure there was any good way to fix it.

Well, I'm fixing the AC on a friend's car right now and have the whole system out of the car and decided to give it a try.

Man, I'm embarrassed at how easy it is.

There is 1 10mm bolt in the center of the AC pulley. I removed it with an impact gun, the pulley will want to turn. Getting the pulley to not spin might be tricky without an impact.

With that off, the inner part of the front pulley will slide right off. The outer part is next, it's just held on with a snap ring. Remove snap ring, pulley comes right off.

SO easy.

With them off, I sanded off the old paint and rust, got it clean, used self-etching primer and a black epoxy paint. Mask off the contact surfaces inside, it's the raw metal that's magnetized to lock the pulley together, you'll see it. I also cleaned up that surface with some degreaser and a light go-over with a scotchbrite pad. The machined inner parts of the pulley that go onto the compressor shaft and the inner bearing I also masked off - basically, I just got paint where the factory had paint.

You can do this with the system charged, I am 99% sure it won't disturb the front seal. The stator is behind this, removing that might lead to problems, but I saw no need to remove it.

Stay tuned, I'm working on REALLY learning the AC system on the FD, look for a big writeup .

Dale

 

PICS!

Oh, and I prefer Option (B) on this subject...... Remove Entire A/C System

 

what no pics....

 

Dale, are you becoming bored or not feeling loved that you posted this!

We love you bro!

 

I will say that I did this years ago, and my compressor seized. It's possible (and probable) something wasn't masked off completely and it damaged the bearing. I didn't really look into it after it happened as A/C wasn't a requirement for how I use my car. Just more of a warning for those wanting to keep their A/C.

 

Pics are attached, I didn't get a super good pic of the pulley before I fixed it, that pic was just for reference on how the lines were run.

Kyle, I imagine the sealed bearing failed, maybe it got cleaner or something in the bearing that messed it up. I made sure to mask that all off well. Also, the metal to metal surfaces where the pulley went on the shaft I put a light coat of grease so it would fit well and be happy .

The pulley system is pretty simple. There's the outer pulley that's turned by the belt and rides on the sealed bearing. The inner pulley floats just above the outer, and they both have metal faces that are brought together by the electromagnet just behind the two pullies. The inner pulley has a rubber core to the body to absorb the shock of the magnet engagement. It's a VERY simple setup.

Dale

 

The engine compart is what really needs cleaning and painting.
Salt from up north or Florida? Glad I live in salt free Houston..

 

Chuck=OG Hater

I think that may be from past battery acid. Pretty sure that isn't Dale's engine bay as he has a BB not VR.....

Ninja Edit: after reading the OP that is indeed a friend's FD

 

The car has been here in Pensacola for many years, but there are signs of weird corrosion on it that leads me to believe it spent its early years up North.

The black crossbrace was pretty rusty and nasty too. I do think some of it was just battery corrosion.

Dale

 

Yes, I'm sure something damaged the bearing. It was more just a warning to others that they can kill their compressor doing this if they aren't careful.