Electromagnetic Clutch
Electromagnetic clutch
Special tools:
999 5597 Puller 999 5597 Puller
999 5596 Counterhold 999 5596 Counterhold
999 5598 Puller 999 5598 Puller
999 5599 Socket with ring 999 5599 Socket With Ring
999 5091 Drift front control arm bushing 240,260,X40 999 5091 Drift Front Control Arm Bushing
999 5087 Socket 999 5087 Socket
999 5600 Socket with ring 999 5600 Socket With Ring
999 5604 Punch 999 5604 Punch
Preparations
Note! Do not disconnect and drain the AC-system.
Remove the multi-groove V-belt
Remove the splash guard. Disconnect the cables.
Disconnect the AC-hoses from the supports.
Remove the compressor (4x bolts) and suspend it by a steel wire.
In gasoline cars: note the extra support.
Remove the clutch disc
Place counterhold 999 5596 Counterhold 999 5596 Counterhold over the clutch disc and remove the nut (diesel) or the bolt (gasoline).
Install the belt pulley 999 5597 Puller 999 5597 Puller and turn it into the clutch disc.
Pull off the clutch disc.
Note! Do not lose the adjusting rings.
Remove the belt pulley
Remove the lock
Install the pulley extractor 999 5598 Puller 999 5598 Puller as close as possible to the electromagnet.
Install the bushing 999 5599 Socket with ring 999 5599 Socket With Ring on the compressor housing.
Pull out the belt pulley from the housing.
Remove the electromagnet
Disconnect the cables from the compressor.
Gasoline: Remove the three attaching bolts.
Diesel: Remove the lock ring.
Remove the electromagnet.
Check and clean all parts thoroughly.
Remove the bearing from the belt pulley (only diesel)
Remove the snap ring.
Press out the bearing with 999 5091 Drift front control arm bushing 240,260,X40 999 5091 Drift Front Control Arm Bushing.
Press in the new bearing with 999 5087 Socket 999 5087 Socket.
Install the lock ring.
Install the electromagnet
Install a new electromagnet (note the guide pin) and install bolts or new lock ring (diesel) with the bevelled side up.
Change the cables.
Tighten the bolts to 10 Nm
Install the pulley
Tap carefully on the belt pulley with a plastic hammer.
Install extractor 999 5598 Puller 999 5598 Puller and bushing 999 5600 Socket with ring 999 5600 Socket With Ring on the belt pulley and press the guide bushing in place.
Force up the belt pulley (extractor behind attaching eyes or behind the hook for the housing).
Install the lock ring with the bevelled side up.
Install the clutch disc
Install the old spacer rings in place on the shaft, and install the clutch disc.
Use a plastic hammer if needed.
Install the centre bolt or nut.
Note! Use 999 5596 Counterhold 999 5596 Counterhold as counterhold.
Gasoline: tighten to 12 Nm.
Diesel: tighten to 18 Nm.
Check clearance between the clutch disc and the belt pulley with a gauge.
- Measure the height between the disc and the belt pulley.
- Push on the disc and measure the height again.
- The difference is the clearance.
Checking and adjusting the value: 0.3 - 0.6 mm
Correct the clearance with the adjusting rings.
Install the compressor, see steps Compressor Removal and Replacement
Remove the carbon intermediate ring
Diesel: remove the key and felt ring.
Remove the snap ring.
Remove the intermediate ring from the shaft.
Install the special tool 999 5604 Punch 999 5604 Punch in the slot and turn 90 degrees.
Pull out the intermediate ring casing to the right.
Note! clean all parts with compressed air and a lint-free rag.
Check to see if the parts are worn or dirty (especially important if remains of the intermediate ring are present).
Install the new carbon intermediate ring
Note! Do not touch the inner running surface or carbon part with your fingers.
Brush compressor oil on all contact faces in the intermediate ring.
First install the intermediate ring on special tool 999 5604 Punch 999 5604 Punch.
Carefully place the tool with the intermediate ring on the shaft. Do not turn!
Press the intermediate ring into place.
Install the following parts:
- key in the shaft
- adjusting rings
- intermediate rings of felt and the holder (the holder shall be exactly level with the casing); use drift and casing.