Compressor Clutch - Replacement Instruction
88BMW02GROUP 64 Heating and Air Conditioning
Bulletin Number 64 01 87 (1471) Page 1 of 1
Montvale, NJ January 1988 Technical Dept.
SUBJECT: Compressor Clutch Replacement
MODELS: All with Vane Type (Rotary Style) Compressor
Situation: The compressor clutch assembly, complete with bearings, is now available as a replacement kit. Follow the attached repair procedures for proper repairs.
Parts
Information: Cars produced prior to 9/87: Repair Kit P/N 64 52 1 380 071 Cars produced since 9/87: Repair Kit P/N 64 52 1 386 297
Warranty
Information: When defective compressor clutches or noisy pulley bearings are encountered, replacement of the clutch assembly is the approved method of repair.
Effective February 12, 1988 claims for replacement of the entire compressor will not be accepted if only the clutch/bearings are defective.
Compressor Clutch Assembly
Required Tools
Holder P/N 88 88 6 645 020 Socket (10 mm) Socket (12 mm) Puller P/N 88 88 6 645 010 Spanner socket P/N 88 88 6 641 110 Phillips screwdriver Blade-type screwdriver Plastic hammer
Removing
Note: Before removing clutch, determine that compressor is not seized by rotating clutch disc (attached to compressor shaft) either by hand or with holder P/N 88 88 6 645 020.
1. Prevent clutch disc from turning with holder (P/N 88 88 6 645 020) and loosen central bolt with 12 mm socket.
2. Screw in puller (P/N 88 88 6 645 010) and pull off clutch disc.
3. Remove clutch adjusting shims and sleeve from the compressor shaft and/or the recess in the clutch disc.
4. Flatten lock washer tab with blade-type screwdriver.
5. Remove slotted nut with spanner socket (P/N 88 88 6 641 110).
6. Remove lock washer.
7. The pulley can now be removed.
8. Unscrew diode from housing with 10 mm socket.
9. Remove coil mounting screws (6) with Phillips screwdriver.
Installing
1. Attach coil to the compressor using the new Phillips head screws (6) supplied in the clutch repair kit P/N 64 52 1 380 071.
Note: The coil wire must be located on the top of the compressor.
2. Attach the diode to the compressor housing with a 10 mm socket.
3. Place pulley onto the coil housing. If necessary, lightly tap it into position with a plastic hammer.
4. (a) Install a new lock washer (supplied in the repair kit). Make sure the locating tab fits into the groove on the coil housing and the looking tabs face up.
(b) Install the new slotted nut supplied in the repair kit, with the chamfered side facing the lock washer.
(c) Tighten the nut to a torque of 3.5 to 4 N-m with the spanner socket, P/N 88 88 6 641 110.
(d) Use a blade-type screwdriver to bend one tab of the lock washer into a suitable groove of the slotted nut.
5. Use a solvent to remove any grease and oil from friction surface and V-belt groove of the pulley.
Note: Keep solvent away from the pulley bearings.
6. Before mounting the clutch disc, install the sleeve and a 0.5 mm shim (for air gap) into the hub.
7. Mount the clutch disc on the shaft, making sure that both keyways are properly aligned. Lightly tapping with a plastic hammer might be necessary to overcome the slight press fit.
8. Install new bolt (supplied in repair kit). Tighten the bolt with a 12 mm socket, while preventing the clutch disc from turning with holder P/N 88 88 6 645 020.
9. Check air gap. The air gap between clutch disc and pulley must be between 0.3 and 0.6 mm. It can be adjusted by using shims of different thicknesses.
10. Energize the coil and check for proper operation of the compressor clutch.