Compressor Clutch: Service and Repair

Replacing the Compressor or the Magnetic Clutch For the Compressor

Special Tools: 9995596, 9995598, 9995599, 9995600, 1158957, 9995597, from tool kit 9995602

Before starting work on the compressor or the magnetic clutch for the compressor

WARNING: Follow the safety instructions for work on air conditioning systems Refrigerant, safety regulations.

NOTE:
- Read the instructions covering slow and quick leaks Soundproofing panel, replacing.
- When replacing a compressor, always replace O-rings in pipes and quick-release connectors.
- Always plug pipes and couplings when working on the climate control system.

Removing the compressor or the magnetic clutch for the compressor
Common operations
- First read "Before starting work on the compressor or the magnetic clutch for the compressor".
- Disconnect the battery lead.
- Drain the system of refrigerant.

Compressor

Remove:







- The generator (GEN).
- pipe/hose connections







- Disconnect the connector.







- Remove the lower screws.
- Remove the upper screws.
- Release the compressor.
- Remove the outermost screws and the bracket with the LED.
- Remove the compressor and the lower

Magnetic clutch







- Slacken off the screw for the clutch plate using counterhold 9995596







- Remove the clutch plate using puller 9995597.
- Keep the shims.







- Remove the snap ring.







- Pull off the pulley using puller 999 5598 and sleeve 999 5599.







- Remove the solenoid coil.

Installation

Magnetic clutch







- Install a new solenoid coil. Tightening torque: 5 Nm (4 lb.ft).







- Install a new pulley using puller 999 5598 and sleeve 999 5600.

NOTE: Position the tools behind the compressor mountings.







- Install the snap ring.







- Install the shims.







- Install the clutch plate. Tighten the screw using counterhold 999 5596.

Tightening torque: 13 Nm (9.6 lb.ft).

Checking clearance







- Check the clearance between the clutch plate and pulley using feeler gauge:
- The clearance should be 0.3 - 0.5 mm (0.012 - 0.02 in).
- 0.3 mm (0.012 in) clearance all around.
- The clearance should not be 0.6 mm (15/64) at any point.
- Replace the shims if the clearance is not between the given values. The following dimensions are available:
- 0.2 mm
- 0.3 mm
- 1.0 mm

Compressor
- Fill the compressor with oil.
- Position the compressor and the lower screw.
- Position the compressor and loosely install the screws.
- Switch on.
- Install the generator (GEN).

NOTE: Always use new O-rings lubricated with compressor oil.

- Connect the hose/pipe connections to the compressor. Tightening torque: 25 Nm (18 lb.ft).
- Vacuum pump and leak test.
- Fill the system with refrigerant and check for leaks.
- Install the battery lead.