Compressor Clutch: Service and Repair

Removing And Installing Magnetic Clutch

Technical values










Preliminary work

Preliminary work for magnetic clutch
1. Remove air cleaner.
2. Remove drive belt.
3. Remove pressure pipe.
4. Remove throttle housing.

Removing magnetic clutch












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







2. Screw 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- from the compressor.







6. Unscrew the two cap nuts -4- for the fuel cooler.
7. Unscrew the three fastening screws -5- securing the air-conditioning compressor.







8. The connection point for the electric line for the air-conditioning compressor is located behind the oil-filter console. Lever the connector out of the plastic holder and pull it apart.







9. Screw off electric line for the solenoid coil on the compressor:

9.1. Lift the air-conditioning compressor up to allow easy access to the fastening screw -1- for the line connected to the solenoid coil.

9.2. Unscrew fastening screw -1- for the line connected to the solenoid coil.







10. Remove Seeger circlip ring -F- for the solenoid coil using the Seeger circlip ring pliers. Remove the solenoid coil from the compressor housing.

Installing magnetic clutch

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 solenoid coil -D- on the compressor housing. The lock 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 the Seeger circlip ring -F- for the solenoid coil -D- and fit it using the Seeger circlip ring pliers.







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







3. Position pulley -C- and install it with the Seeger circlip ring -E-.
4. Secure electric line on the compressor with the fastening screw.
5. Position the air-conditioning compressor with fuel cooler on the engine and use the three fastening screws -5- to secure it to the engine. - Tightening torque: 23 Nm (17 ftlb.)







6. Fit the two cap nuts -4- for the fuel cooler and tighten them.







7. Connect the electric line for the air-conditioning compressor and clip it onto the bracket behind the oil-filter console.
8. Position the pressure plate -A- and secure in place with the fastening screw -1-. - Tightening torque: 14 Nm (10.5 ftlb.)







Checking the magnetic clutch

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-.

Subsequent work

Subsequent work for magnetic clutch
1. Install throttle housing.
2. Fit drive belt.
3. Fit pressure pipe.
4. Install air cleaner housing.