Compressor Clutch - Removal/Installation
Group: 87Number: 91-03
Date: April 30, 1991
Subject:
Nippondenso compressor clutch removal/installation
Model(s):
All Fox Models with A/C
Condition
Replacement compressors and clutches are now supplied separately, not as an assembly. Removal tools are required to remove the OEM clutch from the compressor.
Service
Service tools V.A.G. 1622 and V.A.G. 1623 are available in limited quantities.
Order Number: TAG16222387ZEL
WARNING:
Automotive refrigerants containing CFC's are hazardous to the earth's atmosphere. To protect our environment, use an Underwriter's Laboratory (UL) approved refrigerant recovery/recycling unit such as Kent-Moore ACR 3, or equivalent, whenever discharging an A/C system.
WARNING:
The A/C system should only be serviced by trained personnel familiar with:
^ equipment use
^ related safety procedures
^ regulations governing the discharging, handling and disposal of automotive refrigerants.
WARNING:
Follow all recommended safety precautions listed in the Repair Manual Microfiche to avoid injury.
CAUTION
Always follow manufacturer's instructions when using a refrigerant recovery/recycling unit.
^ Discharge A/C refrigerant system, use refrigerant recovery/recycling unit
^ Disconnect and plug A/C lines to compressor with suitable plugs to prevent contaminating of receiver drier with moisture
Note:
If the vehicle is received with no refrigerant in the A/C system the receiver drier must be replaced.
Note
Refer to Repair Group 87 of the Repair Manual Microfiche for removal and installation procedures.
^ Remove compressor from vehicle.
Note
All compressor repairs must be performed on a clean dry service bench with a vise.
^ Loosen the center hexagon nut, M 8 use V.A.G. 1622 wrench to hold pulley in place
^ Tightening torque: 20 Nm (15 ft. lb.)
^ Install clutch plate puller tool, V.A.G. 1623, in center and remove clutch plate from compressor.
^ Remove shims from shaft of compressor.
^ Remove snap ring with snap ring pliers.
CAUTION
^ Do not damage pulley when removing from compressor shaft.
^ Tap pulley rotor with mallet to remove from compressor shaft.
Note:
Puller set US 1078 may also be used to remove the pulley rotor.
^ Disconnect clutch coil wires from compressor housing.
^ Remove coil retaining snap ring with snap ring. pliers
^ Remove coil from compressor.
^ For assembly, follow reverse order.
CAUTION:
Use a beam type torque wrench. Damage may result from use of inaccurate "click" wrenches.
A/C Clutch Removal/Installation
Labor Operation Number: 87 27 11 0
Suggested Repair Time: 55 TU
Compressor Installation
^ Install compressor in vehicle.
Note:
Refer to Group 87 of the Repair Manual Microfiche for Mechanical installation instructions including belt tensioning.
^ Remove plugs from A/C lines.
^ Lubricate all O rings on compressor fittings with clean refrigerant oil.
^ Install A/C lines to A/C compressor.
^ Evacuate and charge A/C system.
Evacuate and Charge A/C System
Labor Operation Number: 87 01 61 0
Suggested Repair Time: 75 TU