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  1. #1
    Leaky Lloyd's Avatar
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    AIR CON PULLEY ISSUE

    jesus christ, does anything else wanna go wrong for me this week,, all tyres shagged, new clutch and flywheel just fitted,
    and ive finally found out what a certain rattling is !!!
    its coming from the air con pulley,
    i only get this intermitant rattling when the engines cold,
    me and my mate tested it this evening,
    after taking off the belt, the noise went,, an inspection found the air con pulley to be at some sort of fault,
    there seems to be play in it,, but not side to side like you might expect,, more when rotated, there seems to be a fair bit of travel before it engages the actual motor and it seems the lumpyness of a cold start emphesizes the problem !!!
    has anyone ever had this problem???
    got a cost for parts ???
    is it an easy rememedy? as my mate said it could be something to do with a built in motor clutch as the noise changes when the air con was wapped up full !!!
    again people, any advise would be much appreciated ??

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  3. #2
    marktdisport's Avatar
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    mine went on my golf GTtdi m8 same thing rattling noise etc, managed to get a 2nd hand one for around £40 delivered, fitted regassed and all was good, it seems there was somethink loose inside the clutch housing
    A4 TDI 130 SPORT..
    now sold but still in the family, gone back in time to the cupra R again..

  4. #3
    Leaky Lloyd's Avatar
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    is it a fairly common part mate or did you just get lucky,
    also could you reccomend a good salvo place ???
    not buying new, i never use my air con, too tight,,
    just wind the windows down, !!!
    ooooooooold skoooooooooool !!!! PMSL!!

  5. #4
    marktdisport's Avatar
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    was about 3 years ago mate, just off ebay, try a search for a4 breaking theres a few on there bud.... ive known to around 3-4 that the clutchs have siezed and permanatly stuck in
    A4 TDI 130 SPORT..
    now sold but still in the family, gone back in time to the cupra R again..

  6. #5
    Leaky Lloyd's Avatar
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    ah, right bud, thanks, !!!
    seen an actual pulley on there for 60 !!!
    few different sorts though aint there ?
    ill let me mucca take the old one off 1st !!!
    cheers dude !

  7. #6
    pauldazzle's Avatar
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    I've got the same thing at idle. If I raise the rpms a fraction the rattle stops. Had a good look at it on a ramp yesterday, & there doesn't seem to be any play in the pulley so I think it must be the clutch.
    A4 Avant B6 1.9 TDI 130 Sport (6) Moro Pearl Blue, GMBH S Line Kit, Decat, 165bhp remap, EGR delete, K&N panel, Dunlop SP Sport Max, Full Leather, Cruise Control, Full DIS, Bose, Audi phone prep, Cooled Glove Box, Rear privacy glass, Rear parking assist.
    2003 Seat Ibiza 1.2 TSI FR in Lima green.

  8. #7
    mattyboyc's Avatar
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    Did mine about a year or so ago, got a complete pump from GSF for around £80ish (trade), trouble is labour time, front bumper off job but if your doing it yourself it's not a problem, as for being too tight to use your air con, if you actualy look at the genral figures on air con Audi reckon it is cheaper to use your climate/air con than it is to have your window/s open 1-2 inches because of the increased drag ect.
    A4 AVANT 1.9TDI 130 SPORT:
    18" RS6'S//TWIN EXHAUST//ALLARD EGR DELETE//AERO WIPERS//B7 KEYS & ENGINE COVERS//BLACK OPTICS //FRONT & REAR S-LINE BUMPERS//TAILGATE SPOILER//S4 HEADLIGHTS,GRILLS & DOOR BLADES//RS4 RARB & PEDALS//FRONT,REAR & FOOTWELL AMBIENT LIGHTING//PUDDLE LIGHTS//FAN JETS//MEDIA SYSTEM//T.V//7" HEADREST MONITORS//REAR BLINDS//REVERSE CAMERA// CRUISE & DIS


  9. #8
    Leaky Lloyd's Avatar
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    Thumbs up

    fixed mine today,
    the air con pulley has some rubber buffers in it, these had worn down so basially where not buffering the lumpyness of a cold start,,
    fitted a new pulley
    100% sorted now !!! bang on
    pulley and labour was £120,, sounds sweet as a nut now !!!
    well happy with it !

  10. #9
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    mine is really bad will rattle when on idle and the noise changes when you hit the ECON button!

  11. #10
    marktdisport's Avatar
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    Quote Originally Posted by Leaky Lloyd View Post
    fixed mine today,
    the air con pulley has some rubber buffers in it, these had worn down so basially where not buffering the lumpyness of a cold start,,
    fitted a new pulley
    100% sorted now !!! bang on
    pulley and labour was £120,, sounds sweet as a nut now !!!
    well happy with it !
    nice 1 m8y
    A4 TDI 130 SPORT..
    now sold but still in the family, gone back in time to the cupra R again..

  12. #11
    pauldazzle's Avatar
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    Have you got the part number for the pulley?
    A4 Avant B6 1.9 TDI 130 Sport (6) Moro Pearl Blue, GMBH S Line Kit, Decat, 165bhp remap, EGR delete, K&N panel, Dunlop SP Sport Max, Full Leather, Cruise Control, Full DIS, Bose, Audi phone prep, Cooled Glove Box, Rear privacy glass, Rear parking assist.
    2003 Seat Ibiza 1.2 TSI FR in Lima green.

  13. #12
    Leaky Lloyd's Avatar
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    ill try and get it mate, with regaurds to no play on the pulley, if you take the belt off, and turn the pulley in both directions you will feel some play before it engages the air con pump/motor,, thats the noise your hearing, !!
    ill get me mate to forward some pics of the pulleys, new and old, aswell !!

    the part was ordered from the trade part specialists, part number s4f0260810g
    Last edited by Leaky Lloyd; 18th February 2012 at 17:11.

  14. #13
    pauldazzle's Avatar
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    Quote Originally Posted by Leaky Lloyd View Post
    ill try and get it mate, with regaurds to no play on the pulley, if you take the belt off, and turn the pulley in both directions you will feel some play before it engages the air con pump/motor,, thats the noise your hearing, !!
    ill get me mate to forward some pics of the pulleys, new and old, aswell !!
    Great stuff. Where did you get the pulley kit?
    A4 Avant B6 1.9 TDI 130 Sport (6) Moro Pearl Blue, GMBH S Line Kit, Decat, 165bhp remap, EGR delete, K&N panel, Dunlop SP Sport Max, Full Leather, Cruise Control, Full DIS, Bose, Audi phone prep, Cooled Glove Box, Rear privacy glass, Rear parking assist.
    2003 Seat Ibiza 1.2 TSI FR in Lima green.

  15. #14
    Leaky Lloyd's Avatar
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    just edited last post with details mate,, not a kit though, just a pulley,, the noise has completely gone,, woop woop !!!

  16. #15
    Leaky Lloyd's Avatar
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    [IMG][/IMG]

    top ones the new one obviously, and note the lack of rubber buffers in the bottom on as opposed to the new one,,
    he says they didnt completey wear out but where so worn when he removed it they fell out, and should have been pushed in snuggly like the top set !!

    the bearing itself wasnt too bad, (green ring bottom and orange on the top one)
    completely on its arse the old one !!!

  17. #16
    pauldazzle's Avatar
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    TPS quoted me £110 or £140 for the pulley depending on which compressor my car has fitted
    A4 Avant B6 1.9 TDI 130 Sport (6) Moro Pearl Blue, GMBH S Line Kit, Decat, 165bhp remap, EGR delete, K&N panel, Dunlop SP Sport Max, Full Leather, Cruise Control, Full DIS, Bose, Audi phone prep, Cooled Glove Box, Rear privacy glass, Rear parking assist.
    2003 Seat Ibiza 1.2 TSI FR in Lima green.

  18. #17
    Leaky Lloyd's Avatar
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    what year and model is yours mate, looking at your signature it looks exactly the same as mine so i should imagine its the same pulley
    b6 avant sport tdi 130 6 speed with s-line (gmbh ?) kit
    can try and find out a bit more for you !
    still have the paperwork somewhere and i can text my mechanic !

  19. #18
    pauldazzle's Avatar
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    Yeah it's the same as you & 2004.
    A4 Avant B6 1.9 TDI 130 Sport (6) Moro Pearl Blue, GMBH S Line Kit, Decat, 165bhp remap, EGR delete, K&N panel, Dunlop SP Sport Max, Full Leather, Cruise Control, Full DIS, Bose, Audi phone prep, Cooled Glove Box, Rear privacy glass, Rear parking assist.
    2003 Seat Ibiza 1.2 TSI FR in Lima green.

  20. #19
    Leaky Lloyd's Avatar
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    right mate, these are the only details worth mentioning on the t.p.s receipt

    item 012
    part number S4F0260810G
    cost £127.92

    suppose you could try giving your local branch the invoice number ive got, ill pm that to you, if they can get the invoice up they should be able to see the actual part sold !
    other than tht my mate says, go into a local audi dealer and tell them the part you need and give them the chassis number, they should then be able to tell you the part your car needs, then simply go down to t.p.s and hopefully get it cheaper !
    failing this, you will need to get the part number off the aircon pump !!!

  21. #20
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    This is very interesting as I have the same Clutch knocking noises......my garage recommends replacing the WHOLE compressor but it sounds like it could just be the pulley dampers!? Is that right?
    Audi Avant A4 54 1.9Tdi Quattro & Leon Cupra R 2005 1.8T remapped to 275bhp

  22. #21
    pauldazzle's Avatar
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    Quote Originally Posted by Funkyfin2000 View Post
    This is very interesting as I have the same Clutch knocking noises......my garage recommends replacing the WHOLE compressor but it sounds like it could just be the pulley dampers!? Is that right?
    Yep it's usually the pulley. TPS £125ish for a pulley kit.
    A4 Avant B6 1.9 TDI 130 Sport (6) Moro Pearl Blue, GMBH S Line Kit, Decat, 165bhp remap, EGR delete, K&N panel, Dunlop SP Sport Max, Full Leather, Cruise Control, Full DIS, Bose, Audi phone prep, Cooled Glove Box, Rear privacy glass, Rear parking assist.
    2003 Seat Ibiza 1.2 TSI FR in Lima green.

  23. #22
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    Taa, Going to get them to order pulley set and compressor and once it's off, see which needs doing.....Will let you know how we get on...
    Audi Avant A4 54 1.9Tdi Quattro & Leon Cupra R 2005 1.8T remapped to 275bhp

  24. #23
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    Garage getting in the compressor and the pulley.

    Pulley kit from TPS is £158.50 + VAT! So with fitting nearly £300....

    It's almost just worth getting the whole compressor as it would be nice to have the Air Con regassed and serviced (which is £50 anyway normally - and is included with the air compressor changeover)

    We shall see tho!

    Going in Next Thursday, will let you know....
    Audi Avant A4 54 1.9Tdi Quattro & Leon Cupra R 2005 1.8T remapped to 275bhp

  25. #24
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    Goes in today....so will see how we get on and update!
    Audi Avant A4 54 1.9Tdi Quattro & Leon Cupra R 2005 1.8T remapped to 275bhp

  26. #25
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    Leaky Lloyd you are a genius! That was the exact issue...the rubbers were almost completly disintegrated!

    All sorted with a new pulley! £107 cost price from TPS + VAT and fitting!

    Better than £430 for the Air Con Compresosor!]#


    Thanks Agan!!
    Audi Avant A4 54 1.9Tdi Quattro & Leon Cupra R 2005 1.8T remapped to 275bhp

  27. #26
    fourcircle's Avatar
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    would this potentially affect the ability of the /c to work properly? I don't think I've noticed a rattle but my A/C is a bit half arsed just now and I was going to go for a re-gas but don't want to fork out for that and have to do it again if there's another issue underlying
    Anybody selling a polisher? PM me.
    -----------------------------------
    A4 B6 3.0 Quattro Sport Avant
    -----------------------------------

  28. #27
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    Hmmm it could affect I guess but pretty slim chance...It could stop the pulley fully engaging.

    I had an air con service too, and they found my car only had 175ml of gas in the system rather than the full 500ml....its probably never been topped up in the lifetime of the motor...

    Just deciding on a remap now....they downloaded my standard map ready to send off for modification........just gotta say YES now!
    Audi Avant A4 54 1.9Tdi Quattro & Leon Cupra R 2005 1.8T remapped to 275bhp

  29. #28
    fourcircle's Avatar
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    I don't get it.. what's stopping you from saying yes? In my experience the only thing is usually a woman!

    I think i'll go for a regas as a first step as my car probably hasn't had one since new. not that I can see from the service history anyway
    cheers
    Anybody selling a polisher? PM me.
    -----------------------------------
    A4 B6 3.0 Quattro Sport Avant
    -----------------------------------

  30. #29
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    The key issue with this problem is the rattling....so the car was rattling badly...especially at start up, originally the garage thought it was the clutch which sits inside the compressor meaning new compressor.... (although I hear you can potentially change it but its not a seperate audi part)

    I asked my top garage BVR Automotive to get both the new pulley kit and the air Con compressor and do some investigation based on Leaky Lloyds findings...

    Turned out the noise was the rubbers in the picture above, being exactly the same as Lloyds....non existant!!!

    New pulley and rubbers in the pulley kit sorted it!

    My air con wasn't great...but upon checking only had 175ml in it....once topped up fine....the loweness of the air con was probably due to age.....

    What im saying is, if you don't have the clattering noise then its likely you just need an air con service... £50 from BVR for a full vacumm, leak test, smoke bomb and regas to 500ml!
    Audi Avant A4 54 1.9Tdi Quattro & Leon Cupra R 2005 1.8T remapped to 275bhp

  31. #30
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    How easy is it to change the pulley, does the bumper have to come off?

  32. #31
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    Quote Originally Posted by Jules View Post
    How easy is it to change the pulley, does the bumper have to come off?
    Nope bumper doesn't come off... Just removed locating dowels for compressor and drop it down to dissamble.
    Audi Avant A4 54 1.9Tdi Quattro & Leon Cupra R 2005 1.8T remapped to 275bhp

  33. #32
    pauldazzle's Avatar
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    No bumper doesn't have to come off.
    The shaft on my compressor was goosed so I'm going to have to get a new one . A warning to do this job before it gets too late. On mine the rubber bearings had almost dissappeared to nothing & part of the bearing assembly had snapped off damaging the recess for one of the circlips.
    Prices for a new compressor range from £200 to £800!!!!!!!!!!.
    I have a brand new pulley for sale now.
    Last edited by pauldazzle; 3rd December 2012 at 15:23.
    A4 Avant B6 1.9 TDI 130 Sport (6) Moro Pearl Blue, GMBH S Line Kit, Decat, 165bhp remap, EGR delete, K&N panel, Dunlop SP Sport Max, Full Leather, Cruise Control, Full DIS, Bose, Audi phone prep, Cooled Glove Box, Rear privacy glass, Rear parking assist.
    2003 Seat Ibiza 1.2 TSI FR in Lima green.

  34. #33
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    Cheers all hopefully will be doing this at the weekend

  35. #34
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    How do you get the pulley off

  36. #35
    pauldazzle's Avatar
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    We had my car up on a 2 post ramp, which made the job much easier.
    Slackened belt off then removed the compressor from it's mounting, put a gearbox stand under it to support it while we worked. Remove the bolt from front of the pulley & remove circlips, release the pulley, fit new pulley, & use some thread lock on the pulley bolt when reassembling. Refit the compressor, & tension belt.
    A4 Avant B6 1.9 TDI 130 Sport (6) Moro Pearl Blue, GMBH S Line Kit, Decat, 165bhp remap, EGR delete, K&N panel, Dunlop SP Sport Max, Full Leather, Cruise Control, Full DIS, Bose, Audi phone prep, Cooled Glove Box, Rear privacy glass, Rear parking assist.
    2003 Seat Ibiza 1.2 TSI FR in Lima green.

  37. #36
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    Struggling removing the front pulley nut

  38. #37
    pauldazzle's Avatar
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    We had air tools. Pulley nut came off after about 10 secs.
    A4 Avant B6 1.9 TDI 130 Sport (6) Moro Pearl Blue, GMBH S Line Kit, Decat, 165bhp remap, EGR delete, K&N panel, Dunlop SP Sport Max, Full Leather, Cruise Control, Full DIS, Bose, Audi phone prep, Cooled Glove Box, Rear privacy glass, Rear parking assist.
    2003 Seat Ibiza 1.2 TSI FR in Lima green.

  39. #38
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    Quote Originally Posted by pauldazzle View Post
    We had air tools. Pulley nut came off after about 10 secs.
    tried that and it rounded the nut so now chiseling away at the aluminium around it

  40. #39
    pauldazzle's Avatar
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    Bummer. Guess we were lucky on that one then.
    Because of the state of the shaft on my compressor, I'm now running without the compressor with a short belt fitted. The car feels noticeably quicker so for the moment & I'm no big hurry to replace the compressor as use of the AC at this time of year is minimal. Think I'll wait for next spring to arrive, & sort it out then.
    A4 Avant B6 1.9 TDI 130 Sport (6) Moro Pearl Blue, GMBH S Line Kit, Decat, 165bhp remap, EGR delete, K&N panel, Dunlop SP Sport Max, Full Leather, Cruise Control, Full DIS, Bose, Audi phone prep, Cooled Glove Box, Rear privacy glass, Rear parking assist.
    2003 Seat Ibiza 1.2 TSI FR in Lima green.

  41. #40
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    Quote Originally Posted by pauldazzle View Post
    Bummer. Guess we were lucky on that one then.
    Because of the state of the shaft on my compressor, I'm now running without the compressor with a short belt fitted. The car feels noticeably quicker so for the moment & I'm no big hurry to replace the compressor as use of the AC at this time of year is minimal. Think I'll wait for next spring to arrive, & sort it out then.
    cheers for your help earlier, managed to get the pulley off but have left the bolt in place unable to remove. Hoping I can get the pulley on and loctite it into place, if it goes wrong I could put the shorter belt on, what belt did you order out of interest?

 

 
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