G60 Aircon pump???

[stoph-16v 0]

Hi all!

 

Been quite a while since I posted on here. I sold my Corrado and got a G60 Golf with Aircon, which I am hoping you fellows may be able to help with. Seeing as I know to more Corrado G60's than Golf G60's I thought I'd ask you guys :wink:

 

Recently it had been "sticking" on start up, like nothing would turn over. You could hear the starter trying, but it just wasn't having it. It's not until you give it a serious jump (revving the working car loads), that it would start, and even then it would sound as if the engine was really struggling. (suggesting to me, a high load on the engine, something siezing/sticking).

 

Then a rather nasty scraping noise started from the front drivers side of the engine (right by the charger). So, I took the car off the road to find out what it is, thinking I need a new charger or a service. After trying to turn the engine over with a spanner on the camshaft, no joy! Nothing was moving, so I thought maybe my engine had siezed.

 

Upon further inverstigation, yesterday, I removed the charger belt, and the only pulley not moving is that of the Air-conditioning pump. It seems to have some wierd kind of clutch mechanism on the pulley. You can turn the pulley centre, but the toothed part of the pulley doesn't move at all, and is solid! My bro did some snooping around lastnight, and said he thinks it is an electro magnetic coupling????? Is this true???

 

It is at this point I thought I'd come here, and ask if anyone has any ideas about the setup/replacement/function of these aircon pumps?

 

Please help!!!

 

Cheers,

 

Chris H

 

PS - I picked up a cracking little PoloGT on Saturday for a runabout until the G60 is back on the road. 400 quid, and it is awesome!!! I haven't had this much fun in a car for ages, 2nd 3rd and 4th are all amazing! Got a set of BBS RM's for my G60, so the Corrado style BBS currently on the G60 (are they RA's) will go onto the Polo with a lowering kit ;D ;D

[stoph-16v 0]

BTW, I already got a bollocking on the NoRice forum for turning over my engine using the camshaft! So I know not to do that in future!

 

Just thought I'd save everyone the hassle of telling me again :wink:

[stoph-16v 0]

Is there anyone with AC on their G60? Anyone at all, I can't find any help on this puppy! :(

[Henny 0]

OK, I don't have aircon on either of my G60s (yet ;) ) but from what you've said, it does sound like the pulley is the fault. IIRC it's VERY possible that the pulley IS engaged via and electro-magnetically operated clutch system within that pulley so it's looking very possible that this pulley's clutch has given up the ghost and seized up...

 

If you log into http://www.dubforce.net you'll find a load of people over there with Golf G60s who may be able to help a little more and may even have the part you need for sale... ;)

[G60Jet 1]

sound to me like the aircon kompressor is needing a service, if the pully/clutch is playing up that means the kompressor is not turning correctly and the seals will be drying up and the gas will leak out eventually. I'd take it and get it looked at.

[stoph-16v 0]

Nice one guys. ;)

 

Indeed it is the clutch on the pulley. I haven't seen a system like this before so I was a little foxed.

 

For the benefit of those interested, it seems like there is a clutched pulley, which engages the drive to the compressor/pump electromagneticaly, when you turn on the AC.

 

The toothed part of the pulley on mine just will not turn at all, where as the centre section of the pulley will, so something is wrong with the clutch mechanism somewhere. One thing I don't get, is if the centre part will turn, and the toothed part is clutched, why won't the toothed part turn the centrepart with it??? Maybe it's just a stone or something lodged in the toothed part of the pulley? It is hard to see, had to remove my Alternator, airbox, and charger, just to get a look, it may be worth me taking a better look?

 

Unfortunately, because the AC comes off the Charger belt, the whole car is scuppered by this one little fault, kinda annoying, but there you go!

 

Anyway, nice work guys ;) ;)

[h100vw 0]

With the aircon pump off, can you not run a std G60 belt to use the car??

 

I have air on my syncro but haven' got around to gassing it up yet. If the good weather stays I might have to though. Those pumps look pretty std across the VW range. You may be able to get one off a more modern VW if needed.

Gavin

[stoph-16v 0]

Not sure tbh, I have a feeling that the standard belt would foul on the AC pulley. But I can only look at it from the top so it's not too clear.

 

Plus it would be easier to replace/repair whilst it's all stripped down (the alternator, airbox, and charger are out at the moment) better than stripping it all down again.

 

Plus, no sunroof, so the AC is a requirement in a black car with black leather!!! ;)

 

Get it gassed mate! They are, quite literally, cool! 8)

[24V Renshaw 0]

I had Air-con on my G60 and it sounds odd to me what yours is doing. As you said the outer pulley should spin freely until the 12v is put on the electromagnetic clutch at which point it engages and starts turning the inner part and in turn the compressor. I would suspect its more likely that there is something jamming the outer part of the pulley be it a stone or a bolt thats worked loose?

I would remove the aircon compressor and have a look. I wouldn't think its the clutch or compressor at fault as they sound as though they are doing what they should do.

Have you tried turning the outer part of the pulley in both directions?

 

Jay

[stoph-16v 0]

Nice one Jay! ;) The thought had occured to me too (as mentioned above).

 

At the moment I can't see the pulley clearly, need to get under the car and have a good look (it's pretty low down, and I had no ramps at the weekend).

 

Yeah tried to turn the toothed part of the pulley either way and no joy! The centre turn without any problems though, this is what led me to think it could be jammed with something.

[borderair 0]

AC compressors work with an electromagnetic clutch assembly - These basically have 3 components -

1 - Clutch rotor - this is what the belt runs on

2 - Coil - This is an electro magnet

3 - Armature plate - This is a sprung steel plate that when the magnet is energised contacts the rotor (engaging drive to the compressor)

 

With no 12v feed to the coil an air gap should exist betwwen the rotor and the armature plate (normally 0.3mm - 0.8mm)

 

The air gap is adjusted by removing the small bolt at the center of the armature plate and placing shims behind it.

 

Check that you havent got an electrical problem first by unplugging the terminal from the compressor

 

If you want to check your coil if should measure approx 4ohms to the comp body

[stoph-16v 0]

Ah! Maybe this is why it wasn't working??? What was that gap sposed to be again Borderair? ;)

 

Still, stripping down most of the one side of the engine has pushed me to rebuilt the whole lump! Get it all balanced and ported so it runs and breathes as it was meant to, get the charger done whilst it's off, get it looking nice and tidy, but not garish and overchromed! Put my BBS RM's on it, then get it to a few shows. Say hi if you see me about ;)

 

Cheers for all the help fella's ;)

 

Chris

[G60ING 0]

The clutch set up dead. it looks like the pulley is at an angle. Here in the USA every G60 has A/C from the factory. I like A?C on days when when its above 85 degrees F and high humidity whic is everyday in the summer.

 

I have seen pulley failures like this before but it is somewhat rare. I would suggest trying to get another used or used a/c Compressor. The biggest problem I have with getting a good used a/c compressor is that the lines are steel and the compressor's threads are al and the steel lines are often corroded onto the al housing and will shread the threads of the compressor when removed. My suggestion is that you do not throw this pump away as they are rebuildable. If you can find one with bad threads for the a/c lines you can take the rear assembly from your and swap it onto the other compressor. Just make certain you get a new gasket for the compressor from the VW dealer.

 

Also I have found that its some times easiest to keep the engine assembled and to just remove the bumper, grill, core support, radiator and a/c condensor to access the a/c Compressor.

 

Or you can remove the front cross member which hold the front motor mount

[stoph-16v 0]

Yeah it is well and truly dead! I think the bearing may have collapsed inside.

 

I have managed to source a second hand one, so we'll see how that goes!

 

Will keep this incase there is anything I can salvage off it as you say! Didn't know that all US G60's had AC though, interesting!

 

Not sure about the Corrado, but this is a Mk2 Golf, so I think the setup is different, not by much I'm sure though. I do remember thinking it would be easier to get to from the bottom, but my bro who is the more experienced mechanic out of the two of us said it would be easier from the top...? Plus the charger had to come off anyway for a rebuild so...?

[stoph-16v 0]

Hi all, I found this...

 

http://cgi.ebay.co.uk/ws/eBayISAPI.dll? ... %3AIT&rd=1

 

And on my ETKA part catalogue, it says the clutch assembly is

PART NUMBER 357 820 811 A,

 

The guy on Ebay says the kit is

PART NUMBER 1JO 820 811 L.

 

Both 820 811...? Can anyone tell me if this will fit my AC Compressor?

 

This is the last part of the puzzle!!!!! ;) ;)

[G60ING 0]

The Golf if it is not a G60 will not work as the pully is made for V belt like used on the PS and water pump.

 

yes all Corrados in the USA had very few options. I think the options besides color was leather, heated seats, ABS on G60s as VR6 it was mandatory, and sunroofs which only a few came without. All other options were standard

[stoph-16v 0]

It is a G60 Mk2 Golf. ;)