Introduction: VW Audi Seat Skoda Air Conditioning Compressor Pump Clutch Hub Plate Disc 5N0820803, 5N0820803A, 5N0820803E, 5K0820803A Repair Fix Kit Instructions Install Guide

Picture of VW Audi Seat Skoda Air Conditioning Compressor Pump Clutch Hub Plate Disc 5N0820803, 5N0820803A, 5N0820803E, 5K0820803A Repair Fix Kit Instructions Install Guide

The Problem

It is a common fault on these air conditioning compressors for the bolt on the shear plate to loosen, causing the splines within the shear plate to wear leading to loss of air conditioning.

These air conditioning compressor pumps all suffer the same common fault. The bolt which retains the shear plate (attached to the drive pulley) to the pump shaft loosens over time. If spotted early the bolt can be seen unwinding itself, eventually it loosens completely and is lost. The pulley will continue to spin with the engine causing the splines within the shear plate to strip. Once this happens the air conditioning pump will no longer function and produce cold air as the pully can no longer drive the pump. Previously the only solution was to replace the complete compressor at vast expense. We now provide just the shear plate and bolts so you can repair your compressor and restore the A/C at a fraction of the price.

Symptoms of the fault

Symptoms include; no cold air from the air con system and or excess noise from the air conditioning compressor. When the system all appears OK - topped up, no leaks, all seems OK via VCDS logs it is worthwhile inspecting the bolt on the shear plate as this is likely the fault. You should be able to observe the bolt protruding from the compressor (if not yet lost) and the screw not turning despite the pully turning. This is a clear indication that the bolt and shear plate are damaged. Our kit will remedy this.

Vehicles affected and compatibility

Our kit will repair these compressors with this fault:

5N0820803, 5N0820803A, 5N0820803E, 5K0820803A.

Please check the part number on your compressor before ordering, we cannot confirm with 100% certainty from vehicle make / model.

Will fit the Delphi compressor only.

Some models affected:

Seat:

Leon, Altea.

Skoda:

Octavia, Fabia.

Volkswagen VW:

Golf MK 5 MK 6, Eos, Beetle, Caddy, Jetta, Toureg, Passat, Touran, Tiguan, Bora, Polo, Scirocco.

Audi:

A1, A3.

Our solution

Fit our replacement shear plate and bolts and restore your air conditioning compressor to full output.

Our replacement shear plate is a direct replacement for the damaged OEM part. Simply remove the old shear plate and replace with ours, this can normally be done in situ (please check out our video and instructions for guidance) and restore full function to your air conditioning. We also include 4x replacement bolts so all components are included to restore cold air. Providing a massive saving over replacing the complete compressor. A very common fault resolved by our repair kit.

You will receive

1x shear plate

4x bolts

Available exclusively from X8R Ltd

www.x8r.co.uk

Step 1: Remove 4x Shear Plate Bolts

Picture of Remove 4x Shear Plate Bolts

Install can normally be performed in situ on the vehicle, our guide is carried out on the bench to clearly show the process of replacement.

Using a T30 Torx bit remove the Four bolts holding the shear plate to the drive pulley.

Step 2: Prise Off the Shear Plate

Picture of Prise Off the Shear Plate

Using a large flat bladed screw driver lever between the shear plate and the pulley to prise off the shear plate.

Step 3: Shear Plate Damage

Picture of Shear Plate Damage

Here you can see the damage to the shear plate caused by the retaining bolt loosening, the splines have been damaged leading to the shear plate no longer engaging with the compressor pump splines.

You can see here our replacement shear plate with the splines in good condition.

Step 4: Push Fit Our New Shear Plate

Picture of Push Fit Our New Shear Plate

Push our shear plate on to the pump splines.

Gently tap the shear plate with a rubber mallet to engage the splines, just enough so our bolts can be fitted to draw in the splines fully.

Step 5: Fit Our Replacement Bolts

Picture of Fit Our Replacement Bolts

Fit our replacement bolts and tighten fully, this will pull the shear plate in to position and fully engage with the pump splines.

We recommend applying a thread locking compound to the bolts.

Step 6: Check Repair

Picture of Check Repair

This completes the repair. We recommend periodically checking the shear plate bolts for tightness.

If you need any further guidance on this install or would like to purchase the parts shown please call us on +44 01843 446643 or email us at sales@x8r.co.uk . Please also check out our instruction guide on YouTube. www.x8r.co.uk

Installation is carried out at installers risk, if unsure please contact us or a professional, X8R Ltd cannot be held responsible for any adverse result of installing this product or any injuries caused by install, if in doubt ask a professional. All images and texts are copyright X8R Ltd 2016

Comments

Mjtrinihobby (author)2016-08-05

Awesome work!

zygzor (author)2016-08-02

Good instructable, thanks.
My A3 AC starts freezing only after a long drive or doesn't at all, specialy on a very hot days. The system has no leaks.
Could this be the solution?
Thanks.