97 850 - How to replace A/C compressor pulley bearing?

Post by **burnout8488** » 10 Dec 2013, 01:34

Going through gf's new 97 850. Manual Non-turbo w/216k.

Most of the pulleys are making noise, including the A/C compressor when it freewheels. It works just fine, but the pulley has some resistance when it's spun and is making a light grinding noise, as if a brake is being applied to it.

I've read a few threads where other members have successfully changed out the pulley bearing. The car currently has a ton of room in the engine bay, I removed the P/S pump and alternator, and the radiator.

What exactly will I need to get this done? A puller for the clutch? Once the clutch is off, does the freewheel pulley just pop off, or do I need a tool for that? And once the pulley is off, is the bearing pressed into the pulley or pressed on to a shaft of some sort? If anyone has pictures of an A/C compressor teardown, I'd love to see.

I also plan on cleaning + repacking the serpentine idler pulley bearing with new grease thanks to some inspiration on the forum too. Love saving money in easy ways like this. Should be just like new when I'm done.

Post by **rspi** » 10 Dec 2013, 05:35

I have never read about someone replacing the AC pulley bearing. I would replace the compressor with a used one.

The same with the idler. I think those bearings are sealed. Get a new one of those.

Post by **cn90** » 10 Dec 2013, 05:52

Here you go...

https://www.matthewsvolvosite.com/forums ... =1&t=39209

Post by **burnout8488** » 10 Dec 2013, 10:54

Thanks cn90. I've been using your thread for inspiration on the bearing repack as well. https://www.matthewsvolvosite.com/forums ... =1&t=50569

After the clutch is removed, do you know what is involved in taking the compressor pulley off? Is there a bolt or is it press fit?

rspi wrote:I have never read about someone replacing the AC pulley bearing. I would replace the compressor with a used one.

The same with the idler. I think those bearings are sealed. Get a new one of those.

Robert - if it was my car and my money, I'd get a junkyard compressor today. However, the budget for finishing this car quickly reached $0 after placing a few orders in the past few days. The pulley I'm repacking was nowhere near "failing," so I think it's a safe bet to repack it to get some more miles out of it. Once the grease is replaced, I can re-install the grease seal and the bearing should spin like new. (Since I didn't damage the seal taking it out)

Post by **burnout8488** » 10 Dec 2013, 12:00

Found a great blown-up view of a Zexel compressor. I don't think this is the exact model our Volvos use but it's a good image of how they're put together, and the clutch pieces look identical. (Probably are)

http://www.ackits.com/diagrams/Zexel.pdf

Looks like I just need to get the clutch off using the method in cn90's link, then remove a snap ring to get the pulley and bearing off.

Post by **cn90** » 10 Dec 2013, 12:07

The AC Pulley is held by a snap-ring.
Simply use snap-ring pliers to remove it.
Then slide the pulley out.

Below is AC Pulley bearing replacement for Denso (NOT Zexel) but the idea is the same:

Just look up Zexel bearing number and find a substitute. Buy a good bearing like Koyo or Nachi and it will last another 200K.

It is 35x62x24mm or 35BD6224 type bearing.

Post by **rspi** » 10 Dec 2013, 12:19

burnout8488 wrote:Robert - if it was my car and my money, I'd get a junkyard compressor today. However, the budget for finishing this car quickly reached $0 after placing a few orders in the past few days. The pulley I'm repacking was nowhere near "failing," so I think it's a safe bet to repack it to get some more miles out of it. Once the grease is replaced, I can re-install the grease seal and the bearing should spin like new. (Since I didn't damage the seal taking it out)

Man, I understand. I just have never heard of people actually taking these things apart successfully and getting use out of them afterwards. I really didn't think about it but I guess that is what re-builders do all the time. Just never read about people DIY. I'd love to repair parts instead of replacing them.

I truly learn new things every day. Please proceed.

Post by **burnout8488** » 10 Dec 2013, 12:25

Thank you so much cn90. Going out to start the job in a little and will order a bearing tonight if I can get the pulley off.

Robert, yeah, it's something that if I can confidently get the seal re-installed with no damage… no different than buying a new bearing, right? (Other than maybe a little wear on the bearing races) If it all goes together smoothly, should be a cheap and somewhat fun learning experience.

I'd almost consider repacking the A/C bearing, but it looks a bit heavier duty, and the one on her compressor now sounds absolutely terrible.

Post by **burnout8488** » 10 Dec 2013, 16:46

Got it! The bearing for the Zexel DKS15-CH compressor is 35x55x20mm. I'll pick one up online tonight and it will hopefully arrive soon.

Took everything off to clean up the terrible power steering leak mess, and ended up getting into a lot more than I expected.

A trick for taking off the A/C clutch: When you're threading in the M5 bolts, screw them in as far as you can, they press against the compressor hub and will push the clutch off for you with no puller needed.

Circlip removed from shaft:

Removed bearing with a 34mm (?) socket and some cleverness with a hammer.

beigg · Post by **beigg** » 10 Dec 2013, 17:07

I just tossed a perfectly fine compressor in the recycler's bin. Coulda had a quick cheap replacement lol