Compressor Clutch: Service and Repair

Compressor Electromagnetic Clutch:

REMOVAL:
1. Remove refrigerant compressor.

Pin Wrench, Special Tool # 000 589 00 05 00:

Holding Spring Plate With Pin Wrench:

2. Remove spring plate (61) using pin wrench (special tool # 000 589 00 05 00), to hold spring plate.
3. Remove snap ring (63) using outside snap ring pliers.
4. Drive off ribbed V-belt pulley (65) using a plastic mallet.

NOTE: If the same pulley is reinstalled, the friction surface of the pulley must be cleaned. If the friction surface displays signs of damage (e.g. due to overheating), the pulley must be replaced together with the spring plate.

5. Remove snap ring (69).

Solenoid Coil Connector:

6. Remove solenoid coil (71). First open plug housing on refrigerant compressor. To open plug housing, unscrew both screws (arrows). Take out cable to solenoid coil. Disconnect negative lead of solenoid coil from refrigerant compressor.
7. Test solenoid coil:
- Warm: 3.75 Amps
- Cold: 4.20 Amps

INSTALLATION:
1. Install the solenoid coil. Push solenoid coil onto dowel pin, tapered side of snap ring must face outwards.
2. Install snap ring (69).
3. Drive on ribbed V-belt pulley (65), using a plastic mallet.
4. Install snap ring (63).
5. Install spring plate (61). Tighten bolt to 16±1.0 Nm.

Checking Spring Plate Gap:

6. Check spring plate gap, 0.5±0.15 mm, and correct with shims (62).
7. Install refrigerant compressor.