Changing Pulley
Burning Brakes
Joined: Jan 2002
Posts: 885
Likes: 0
From: The Woodlands Texas
There are 3 pulleys on the a/c compressor system - one is the big one on the compressor, one is an idler pulley and the last is a tensioiner pulley. You can remove the tensioner and idler pulley using a 15mm socket.
If you have more than about 80,000 miles on the car I would advise replacing both the idler and tensioner pulleys - about $15 each at the dealer. You will want to tackle the idler pulley first (farthest from the compressor) by first loosening the idler pulley bolt, pulling down on the tensioner pulley and then removing the idler pulley. Now you can work each pulley replacement without the single v-belt falling off. You may want to replace the v-belt while you are in there.
The pulleys and v-belt are at the bottom of the engine bay and get hammered with road grit, sludge, etc and that takes a toll on the system.
This is easy work but take your time. Best to jack up the car and work from the bottom to save your back.
Good luck.
If you have more than about 80,000 miles on the car I would advise replacing both the idler and tensioner pulleys - about $15 each at the dealer. You will want to tackle the idler pulley first (farthest from the compressor) by first loosening the idler pulley bolt, pulling down on the tensioner pulley and then removing the idler pulley. Now you can work each pulley replacement without the single v-belt falling off. You may want to replace the v-belt while you are in there.
The pulleys and v-belt are at the bottom of the engine bay and get hammered with road grit, sludge, etc and that takes a toll on the system.
This is easy work but take your time. Best to jack up the car and work from the bottom to save your back.
Good luck.
Drifting
Joined: May 2005
Posts: 1,590
Likes: 1
From: Littleton Colorado
If you have an auto trans then it is not very easy as the cooling lines run right in front of the pulleys. I had no luck using a socket, I could only get it with a wrench and a lot of cussing 
And it is tough to get the tensioner pulley out, and back in, through the cooling lines. I went in from below, so if you have a A4 get it up on ramps first. I may have used a socket with a swivel to get it on, but a wrench to do the tensioning. Do them BOTH as you'll not want to fight it twice.
If you have a manual trans, then it is a LOT easier
And it is tough to get the tensioner pulley out, and back in, through the cooling lines. I went in from below, so if you have a A4 get it up on ramps first. I may have used a socket with a swivel to get it on, but a wrench to do the tensioning. Do them BOTH as you'll not want to fight it twice.If you have a manual trans, then it is a LOT easier
