Repair Procedure

Compressor Components

PREPARATIONS:

Drain water out of engine coolant system. Undo the upper and lower radiator hoses and oil pipe, if any, to the automatic transmission.




Take the tension off the tensioner and remove the drive belt.

REPLACEMENT OF PULLEY/CLUTCH

Remove clutch plate




Install counterhold 999 5596 on the clutch plate as shown. Detach and remove nut in center of clutch plate.




Pull off clutch plate using the puller 999 5597 as shown.




Keep the shims located on the shaft behind the clutch plate. (They normally remain in place on the shaft but can stick to the clutch plate). They must be replaced on the shaft in the same order they were removed.




Remove circlip.

REMOVE PULLEY.




Pull off the pulley using the puller.

Use a puller to remove pulley.




Remove the circlip and the magnetic coil.


UNSCREW THE DIODE END DETACH THE CONNECTOR. REMOVE MAGNETIC COIL.

Install new magnetic coil.




Reconnect the connector and tighten bolt for diode to 5 Nm (3 ft lbs).

Install pulley.

Install pulley so the groove is centered on the stud.




Tap the pulley carefully into position using socket 999 5200 and a hammer.




Replace the circlip.

INSTALL CLUTCH PLATE




Make sure the shims are installed on the shaft in the same order they were removed.

Install clutch plate so the groove is centered on the stud. Tap clutch plate carefully into position using a suitable socket.

Tighten nut to 15 Nm (11 ft lbs)


CHECK CLEARANCE




Check clearance between the clutch and the pulley. Insert a feeler gauge all the way around the gap.

Clearance should be 0.3 - 0.5 mm (0.012" - 0.020").
- 0.3 mm (0.012") should pass between all around
- 0.6 mm (0.024") should not enter at any point

If the clearance is not between the given values, use shims to adjust clearance until it does. Shims are supplied with the kit.

When clearance is within the given tolerances reinstall and tighten the drive belt, then reInstall all other parts removed.

Final operations

Fill with automatic transmission fluid to correct level. Run engine and verify A/C functions.

Check and top up automatic transmission fluid if required.