Compressor Clutch: Service and Repair

Removing And Installing Magnetic Coupling

Technical Values







Preliminary work

Preliminary work for magnetic clutch
1. Remove engine compartment lid.







2. Remove rear wall cover.







3. Remove drive belt.

WARNING: Danger of injury and material damage when using Pentosin.
- Risk of skin irritation and damage to skin.
- Damage to hoses and wiring.

- Wear protective gloves and goggles.
- In the event of contact (eyes or skin), wash immediately with water.
- Collect emerging Pentosin.
- Use caps to protect the wiring against soiling and damage.
- Clean hoses and wiring immediately.

4. Remove Pentosin from the power-steering reservoir by suction and pour it into a suitable container.







5. Release bayonet lock -arrow- on the power-steering reservoir and remove power-steering reservoir.

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. Unscrew rear Torx screw for air-conditioning compressor (M8 x 120) -1- between the pipes of the intake system.







6.2. Unscrew front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2-.
6.3. Disconnect electric plug connection on the air-conditioning compressor's electrical line.







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

Installing the magnetic coupling

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







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







INFORMATION: 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 install with Seeger circlip ring pliers.







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







4. Secure the electric line with the fastening screw -4- on the compressor.
5. Position compressor on engine again and screw down the fastening screws:
5.1. Clip in connector for air-conditioning compressor supply line and clip connector housing into the holder provided.







5.2. Screw in front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2-.







5.3. Screw in rear Torx screw for air-conditioning compressor (M8 x 120) -1- and tighten all three screws for air-conditioning compressor. Tightening torque: 23 Nm (17 ftlb.).







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

Subsequent work

Subsequent work for magnetic clutch







1. Position power-steering reservoir. Lock bayonet lock -arrow- on power-steering reservoir.
2. Replace the quantity of Pentosin removed during removal with new Pentosin and pour this into the power steering reservoir.







3. Turn the tensioning roller clockwise using a ring wrench (a/f 24), position the drive belt and then tension it.
4. Check Pentosin level in power-steering reservoir
5. Install rear underbody cover.







6. Install rear wall cover.







7. Install engine compartment lid.
8. Start engine. Turn the steering wheel from stop to stop while the engine is running in order to bleed the steering system.
9. Check operation of air-conditioning compressor.

Checking the magnetic coupling

Checking air gap of magnetic clutch












1. Check the air gap between the pressure plate and pulley using a depth gauge.
2. Place a rule on the outer edge of the pulley. Use a depth gauge to measure up to the pressure plate. Apply battery voltage to the magnetic clutch 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 using spacers -B-.