A. Delco R4

Operation No. of Job Texts and Work Units, Standard Texts and
Flat Rates 83-0640


Data, test values
Electromagnetic shutoff clutch 12 V Delco 4.9 inch

Power input in amps at 13.5 V Cold 3.9
Warm 3.4







Tightening torques







Special tools


Conventional tools
Socket 14 mm, 3/8" square e.g.Hazet, D-5630 Remscheid

Slip gauge (set) e.g. Hazet, D-5630 Remscheid, Order no.2147

Long-nose pliers 72 A (inside lock) e.g. Hazet, D-5630 Remscheid, Order no. 1846a-1

Pliers for locking ring J 2 (outside lock) e.g. Hazet, D-5630 Remscheid, Order no.1846c-2

Self-made tool
Tool for removing O-ring


NOTE: Removal and installation of the spring plate, clutch body with pulley and solenoid coil, as well as the shaft seal can be performed only with the refrigerant compressor removed.

The clutch body with bearing, pulley and solenoid coil together form a single assembly group. If one component of this assembly group must be renewed, remove the entire assembly group.

a) Removing and installing spring plate

Removing
1 Drain air conditioning system.
2 Remove refrigerant compressor Service and Repair






3 Seal openings with pressure-testing plate 109 589 00 25 00. Then fasten holding device to refrigerant compressor and clamp in a vise.







4 Release refrigerant compressor from holding device 116 589 14 31 00 and fasten again with the drive shaft pointing upwards.







5 Prevent the spring plate (2) turning by using the holding wrench 116 589 04 40 00 and unscrew nut from shaft using 14 mm socket.








6 Screw remover 000 589 07 35 00 into hub, hold tool in place with wrench and tighten central bolt.
7 Remove key in shaft.

Installing
8 Clean friction surfaces of spring plate and clutch body.







9 Insert key (4) into groove in hub so that it projects approx. mm.







10 Place spring plate on shaft such that the key and keyway are in alignment.
11 Place spacing element on spring plate. Insert installation tool 000 589 49 43 00 through spacing element and screw installation tool onto end of shaft.
12 Hold hexagon head of tool in place and screw in central bolt until there is a clearance of approx. 0.1 - 1 mm between friction surfaces of spring plate and clutch body.







1 Nut on drive shaft
2 Spring plan
3 Clutch body
5 Locking ring
6 Bearing for clutch body
7 Pulley
8 Bolt with lock
9 Solenoid coil
10 Locking ring
11 O-ring
12 Slip ring
13 Shaft seal
14 Drive shaft
20 Housing cover


13 Remove installation tool and spacing element.
14 Screw new nut onto shaft (smaller diameter of nut in direction of shaft shoulder) and tighten. Check clearance again.
15 Install refrigerant compressor Service and Repair


b) Removing and installing clutch body with pulley, solenoid coil and bearing

Removing
16 Remove spring plate






17 Remove locking ring (5). Mark positions of solenoid coil terminals.







18 Insert guide element 116 589 05 63 00 over shaft onto head section of refrigerant compressor.
19 Pull off assembly group using puller 000 589 88 33 00.







20 Bend back locks on hexagon-head bolts and remove the 6 bolts (8) with locks.







21 Take pulley from clutch body and remove solenoid coil from pulley.


NOTE: If the bearing (6) of the clutch body (3) must be renewed, perform steps 22 to 24.


Removing bearing







22 Place clutch body (3) on wooden supports and press out bearing (6) using a drift 115 589 02 35 02. It is not necessary to remove the indentations in order to remove the bearing.


Installing bearing







23 Align new bearing (6) accurately on bore of hub and then press in using the drift 115 589 02 35 02.







24 Punchmark bearing at 3 points offset at 120 °C for locking purposes. Do not punch too deeply or the outer race of the bearing may be deformed. Do not use old indentations again.


Installing







25 Insert solenoid coil (9) into pulley (7).







26 Push clutch body (3) into pulley (7) and screw on provisionally using new locks and bolts (8). Coat threads of bolts with Loctite.







27 Place complete assembly group on front housing cover. Before pressing on assembly group completely, ensure that the terminals of the solenoid coil are correctly positioned in relation to the refrigerant compressor and that the three projections on the back of the solenoid coil are in alignment with the three recesses in the housing cover.







28 Insert locking ring (5) for assembly group.
29 Clean friction surfaces of spring plate and clutch body.







30 Rotate pulley with clutch body to check whether pulley is in alignment; readjust pulley a little if necessary.
31 Tighten bolts (8) holding pulley to clutch body. Secure bolt heads in a similar way to that in which the bolts were secured before removal.
32 Install refrigerant compressor.