Compressor Clutch: Service and Repair

Magnetic clutch compressor, replacing

Special tools:
999 5596 Counterhold 999 5596 Counterhold
999 5598 Puller 999 5598 Puller
999 5599 Socket with ring 999 5599 Socket With Ring
999 5600 Socket with ring 999 5600 Socket With Ring
999 5597 Puller 999 5597 Puller
999 5602 Tool kit - repl. shaft seal Sanden comp. 999 5602 Tool Kit - Repl. Shaft Seal Sanden Comp.

As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct.

Preparations

Warning! Read the safety instructions for work on air conditioning systems. See Refrigerant, safety regulations Technician Safety Information.

Read the instructions covering slow and fast leaks. See Oil Air Conditioning (A/C) System, Filling

Note! When replacing a compressor, always replace the O-rings in the pipes and quick-release connectors.

Note! Always plug the pipes and connections when working on the climate control system.




Remove the compressor See Compressor, replacing Service and Repair.

Removing the magnetic clutch compressor




Slacken off the screw for the clutch plate. Use special tool 999 5596 Counterhold 999 5596 Counterhold.




Remove the clutch plate. Use a puller, special tool 999 5597 Puller 999 5597 Puller.
Keep the shims.




Remove the snap ring.




Pull off the pulley. Use a puller, special tool 999 5598 Puller 999 5598 Puller and socket, special tool 999 5599 Socket with ring 999 5599 Socket With Ring.
Remove the magnet coil.

Installing the magnetic clutch for the compressor




Install a new magnetic coil. Tighten. See [1][2]Body and Frame




Install a new pulley. Use a puller, special tool 999 5598 Puller 999 5598 Puller and socket, special tool 999 5600 Socket with ring 999 5600 Socket With Ring.

Note! Position the tools behind the compressor mountings.




Install the snap ring.




Install the shims.




Install the clutch plate. Install 1 screw using a counterhold, special tool 999 5596 Counterhold 999 5596 Counterhold. Tighten.




Check the clearance between the clutch plate and pulley. Use a feeler gauge.
The clearance should be 0.3-0.5 mm.
There must be 0.3 mm clearance all the way around.
Replace the shims if the clearance is not within the given values. The following dimensions are available:
0.2 mm
0.3 mm
1.0 mm

Install the compressor. See Compressor, replacing Service and Repair.