Compressor Clutch: Service and Repair

Removing And Installing Magnetic Coupling

Preliminary work

Preliminary work for magnetic clutch
Remove air cleaner.
Remove drive belt.

Removing the magnetic coupling







1. Use a commercially available strap wrench to securely hold the pressure plate -A- on the air-conditioning compressor, and undo the fastening screw -1-.







2. Screw in an M8 screw -2- into the thread of the pressure plate until the pressure plate -A- can be removed by hand.







3. Take off spacers -B- behind the pressure plate.
4. Use a Seeger circlip ring pliers to remove the Seeger circlip ring -E- on the pulley -C-.







5. Remove pulley -C- on the compressor.
6. Unscrew electric line of solenoid coil on the compressor:
6.1. Remove the three fastening screws holding the air-conditioning compressor -3-.
6.2. Remove the air-conditioning compressor and lift upwards, now the fastening screw -4- for the solenoid coil line is accessible.
6.3. Unscrew the fastening screw -4- for the solenoid coil line.







7. Take out the electric connector -2- for the compressor from between the intake pipes and pull apart.







8. Remove Seeger circlip ring -F- for the solenoid coil with the Seeger circlip ring pliers. Remove the solenoid coil from the compressor housing.







Installing the magnetic coupling

Installing magnetic clutch

NOTE: If a new magnetic clutch is installed, the air gap between pressure plate and pulley must be checked with a depth gauge.

1. Place solenoid coil -D- on the compressor housing. The lock pin -G- must engage in the locking hole -H-.







NOTE: When installing the Seeger circlip ring, the slanted surface of the Seeger circlip ring must point forward.







2. Position Seeger circlip ring -F- for solenoid coil -D- and fit using Seeger circlip ring pliers.







3. Position pulley -C- and fit with Seeger circlip ring -E-.







4. Secure electric line to compressor with fastening screw -4-.







5. Re-fit compressor to the engine and tighten with fastening screws.
5.1. Fit air-conditioning compressor to engine housing with the rear fastening screws and tighten with the three fastening screws -1-. M8: 23 Nm (17 ftlb.)







5.2. Connect the connector and position between the pipes of the intake system.







6. Position the pressure plate -A- and tighten with the fastening screw -1-. Tightening torque: 14 Nm (10.5 ftlb.)







Checking the magnetic coupling

Check air gap of magnetic clutch







1. Check the air gap between the pressure plate and belt pulley with a depth gauge.







2. Place a rule on the outer edge of the belt pulley. Use a depth gauge to measure up to the pressure plate. Apply battery voltage to the magnetic coupling and measure the distance (air gap) to the attracted pressure plate. Always measure at least three points on the pressure plate in order to obtain a mean value. Distance: 0.5 mm ± 0.15 mm
3. If the air gap is not in the tolerance range, it must be adjusted with the aid of the spacer washers -B-.

Subsequent work

Subsequent work for magnetic clutch
Install drive belt.
Install air cleaner.