Compressor Servicing Audi A4 B5

CALSONIC V5 & V6

Note. Due to variety of clutch and shaft seal configurations, obtain appropriate A/C compressor service tools for compressor being serviced.

Note. See the COMPRESSOR REFRIGERANT OIL CHECKING article for refrigerant oil checking/specifications and compressor applications.

Note. Subaru recommends replacing compressor as an assembly.

Removal

1. Using Clutch Disc Wrench (J-41260), remove clutch plate bolt. Using Clutch Disc Puller (J-38874), remove clutch plate. Insert clutch disc puller holder pins into clutch disc holes. Rotate holder clockwise to lock it into clutch disc. Tighten clutch disc puller center bolt and remove clutch disc plate and shims. Remove snap ring. (Scheme 1)
2. Using a puller, remove center pulley. Position puller claws on the edge of pulley to prevent pulley groove from being deformed. Remove clutch coil harness clip, coil external snap ring and clutch coil.

Installation

1. Ensure clutch disc and pulley contact surfaces are clean and free of excessive grooving and/or damage due to excessive heat. Check clutch coil for loose connection or cracked insulation. Replace clutch disc and pulley as a set and/or clutch coil, if necessary.
2. Align clutch coil pin with hole in compressor front head. Install clutch coil harness clip. Using hand press, install pulley and snap ring. Install original shim(s) and clutch disc. Using Clutch Disc Wrench (J-41260), install and tighten center bolt to 10 ft. lbs. (14 N.m). Ensure pulley turns smoothly.
3. Use a feeler gauge to check clearance between clutch plate and pulley. Clearance should be .012-.024" (.30-.60 mm). If clearance is incorrect, add or remove shims as necessary.

Scheme 1

1. Using clutch holder, remove clutch plate bolt. Using an 8-mm bolt threaded into clutch plate, remove clutch plate and shim(s). (Scheme 2)
2. Remove snap ring and pulley assembly. Install Shaft Protector (49 UN01 045) over shaft seal opening. Use a 2-jaw puller to remove clutch coil from compressor.

1. Ensure clutch coil mounting surface is clean. Use coil installer and 2-jaw puller engaged to rear side of compressor front mounts to press coil into place.
2. Install pulley assembly. Install snap ring with bevel side of snap ring facing out. Install shim(s) and clutch plate. Install a new clutch plate bolt and tighten to 97-115 INCH lbs. (11-13 N.m).
3. Use a feeler gauge to check clearance between clutch plate and pulley. Clearance should be .014-.033" (.35-.84 mm). If clearance is incorrect, add or remove shims as necessary.

1. Using clutch holder, remove clutch plate bolt. Using an 8-mm bolt threaded into clutch plate, remove clutch plate and shim(s). (Scheme 2)
2. Remove shaft seal felt. Thoroughly clean seal area of compressor. Remove shaft seal snap ring. Position shaft seal remover over compressor shaft.
3. Push shaft seal remover downward against seal. Ensure end of shaft seal remover is engaged with inside of seal. Rotate shaft seal remover clockwise to expand remover tip inside seal. Pull shaft seal from compressor.

1. Lubricate shaft seal protector and shaft seal with refrigerant oil. Install shaft seal on shaft seal protector so lip seal is toward compressor (large end of shaft seal protector).
2. Install shaft seal protector on compressor shaft. Using shaft seal installer, push shaft seal down seal protector until seal is seated.
3. Remove shaft seal installer and protector. Install a new shaft seal retaining snap ring and shaft seal felt. Install shim(s) and clutch plate. Install a new clutch plate bolt and tighten to 97-115 INCH lbs. (11-13 N.m).
4. Use a feeler gauge to check clearance between clutch plate and pulley. Clearance should be .014-.033" (.35-.84 mm). If clearance is incorrect, add or remove shims as necessary.

Scheme 2

Using Clutch Holder (J-37872), hold pressure plate and remove shaft bolt. Remove pressure plate and adjustment shim(s). (Scheme 3) Remove snap ring. Using universal puller, remove compressor pulley. Remove clutch coil.

Install clutch coil in reverse order of removal. Tighten clutch coil mounting screws to 86 INCH lbs. (9.7 N.m). Ensure snap ring is properly seated. Apply locking compound to shaft bolt and tighten it to 96 INCH lbs. (10.8 N.m). Ensure clearance between pressure plate and pulley is 0.012-0.024" (.30-.60 mm). If clearance is incorrect, add or remove shim(s) as necessary.

Scheme 3

Remove shaft nut while holding clutch plate with Clutch Holder (J-37872). Remove pressure plate and shim(s). Remove snap ring. Using universal puller attached to outer diameter of pulley, and Driver (07947-6340300) in center of pulley, remove pulley. DO NOT engage puller on belt area. Hold puller in place and tighten screw to remove pulley. Remove screw for clutch coil lead. Remove snap ring and clutch coil.

1. To install, reverse removal procedure. Align lug on clutch coil with hole in compressor. Install snap ring with chamfered side facing out. Position pulley squarely over coil. Using Hub Guide (07945-6920500), press pulley onto compressor boss. Maximum press load is 5690 psi (400 kg/cm 2 ) or 882 lbs. (400 kg).
2. Tighten shaft nut to 13 ft. lbs. (18 N.m). Using feeler gauge, ensure clearance between pressure plate and pulley is .014-.026" (.35-.65 mm). If clearance is incorrect, add or remove shim(s) as necessary.

Note. If shaft seal leaks, replace compressor.

CLUTCH COIL & BEARING

1. Remove compressor from vehicle. Place compressor in Holding Fixture (J-41790). Use Clutch Plate Spanner (J-33027-A) to hold clutch plate. Remove compressor shaft nut.
2. Use Clutch Plate Remover/Installer (J-33013-B) to remove compressor clutch plate and hub. (Scheme 4) Hold remover body and turn center screw into remover body to remove clutch plate and hub. Ensure forcing tip on remover/installer center screw is flat or end of shaft/axial plate will be damaged. Remove key from shaft.
3. Remove snap ring. Install Guide (J-33023-A) on front head. Position Pulley and Bearing Puller (J-33020) into inner circle of slots on pulley. Turn puller clockwise in slots. Tighten puller and remove pulley.
4. If bearing is to be removed, remove forcing screw from puller. With puller still engaged in pulley slots, invert assembly onto a solid flat surface. Use a hammer and Bearing Remover (J-9398-A) to drive bearing from pulley. (Scheme 4) NOTE: It is not necessary to remove staking in front of bearing before removing bearing.
5. Disconnect clutch coil lead. Scribe marks on compressor and clutch coil for installation reference. Remove clutch coil using Puller Adapter (J-33023-A) and 2-jaw puller.

Scheme 4

1. Align reference marks made during removal. Using Puller Adapter (J-33024) and Puller Bar (J-8433-1), press clutch coil onto compressor. Ensure clutch coil and installer stay lined up during installation. Using a 1/8" punch, stake clutch coil inner ring in 3 places, 120 degrees apart. Stake size should be 1/2 the area of punch tip and .010-.015" (.28-.38 mm). NOTE: To ensure proper clearance, it is necessary to remove old stake metal before installing a new bearing.
2. If bearing was removed from pulley, place pulley on Support (J-21352-A). DO NOT support pulley on flat surface, or pulley will be damaged. Install bearing in pulley using hammer, Handle (J-29886) and Bearing Installer (J-9481-A).
3. With pulley on support, use Bearing Staking Guide (J-33019-1) and Bearing Staking Pin (J-33019-2) to stake pulley in 3 places, 120 degrees apart. Reposition pulley on support to ensure full support under staking pin. Metal stake should be similar to original stake (down to, but not touching bearing). Position pulley on compressor.
4. Place Bearing Installer (J-33017) and Puller Guide (J-33023-A) over inner race of bearing. Using puller, press pulley onto compressor. Install snap ring. Install key in clutch plate, allowing key to protrude about 1/8" from rear of clutch plate.
5. Install clutch plate on compressor shaft. Using clutch plate remover/installer, press clutch plate onto compressor. Ensure key is still in keyway before installing clutch assembly to its final position. Air gap between friction surfaces should be .015-.020" (.38-.51 mm).
6. Using spanner, install compressor shaft nut. Tighten shaft nut to 12.5 ft. lbs. (17 N.m). Check components for proper rotation.

1. Discharge A/C system, using approved refrigerant recovery/ recycling equipment. Loosen and reposition compressor in mounting bracket. Remove clutch plate and hub assembly. See «CLUTCH COIL &»(/audi/a4/b5-1994-1999/remont/general-servicing-all-makes/#compressor-servicing) BEARING. (Scheme 4)
2. Remove shaft seal snap ring. Ensure all surfaces around seal are clean. Insert Shaft Seal Remover/Installer (J-23128-A) into shaft seal. Rotate handle clockwise to seat seal remover/installer in seal. Remove shaft seal. Using "O" Ring Remover (J-9553-01), remove "O" ring. Ensure shaft and inside of compressor neck are clean and free of foreign material. Thoroughly clean "O" ring groove in front head.

1. Install Shaft Seal Protector (J-34614) over compressor shaft. With shaft seal protector in place, lubricate new "O" ring with refrigerant oil and install it on "O" Ring Installer (J-33011).
2. Insert "O" ring installer in compressor until it bottoms. Move slide on "O" ring installer downward until "O" ring is released into groove. Rotate installer to seat "O" ring. Remove "O" ring installer.
3. Lubricate shaft seal with refrigerant oil. Install shaft seal onto Seal Installer (J-23128-A). Install shaft seal so flared side of lip seal is installed toward compressor. Expand seal using shaft seal remover/installer. Install shaft seal on Seal Protector (J-34614). Place seal protector over shaft.
4. Push shaft seal into compressor using a rotary motion until seal bottoms. Install new snap ring with flat side against seal. Install clutch plate and hub assembly onto compressor shaft. See «CLUTCH COIL & BEARING»(/audi/a4/b5-1994-1999/remont/general-servicing-all-makes/#compressor-servicing) .

1. Hold clutch hub with Clutch Tightener (925770000). Remove shaft nut from shaft. Using Clutch Hub Remover (926130000), remove clutch hub. Use snap ring pliers to remove inner snap ring.
2. Remove pulley and bearing assembly. Remove screws securing clutch coil lead. Remove inner snap ring from clutch coil. Remove clutch coil from front cover.
3. Remove shaft key. Use snap ring pliers to remove shaft seal snap ring. Wrap a rag around compressor shaft. Using Injector Needle (92619000) and refrigerant can, slowly pressurize compressor at low pressure (suction) service port. (Scheme 5) Catch shaft seal seat in rag.
4. Insert Shaft Seal Remover/Installer (926120000) through open end of front cover. Slowly pull out remover/installer to remove shaft seal.

1. Ensure shaft seal contact surface is free of dirt. Lubricate with refrigerant oil. Using shaft seal remover/installer, insert shaft seal.
2. To install clutch coil and hub, reverse removal procedure. Tighten shaft nut to 14-15 ft. lbs. (19-21 N.m). Ensure clearance between pressure plate and pulley is 0.020-0.031" (.50-.80 mm).

Scheme 5

Removal & Installation

1. Using Pressure Plate Holder (07112-76060) and socket, remove center bolt. Thread Puller (07112-66040) onto pressure plate. Hold pressure plate with pressure plate holder and tighten puller to remove pressure plate.
2. Remove shim(s) from shaft. Remove snap ring and, using a plastic hammer, tap pulley off. Remove screw for clutch coil lead. Remove snap ring and clutch coil. (Scheme 6)
3. To install, reverse removal procedure. Tighten shaft bolt to 10 ft. lbs (14 N.m). Using feeler gauge, ensure clearance between pressure plate and pulley is.014-.026" (.35-.65 mm). If clearance is incorrect, add or remove shim(s) as necessary.

Scheme 6

1. Hold clutch plate with Clutch Holder (00007-10331) and remove shaft nut. Install Clutch Disc Remover (4992-02-020) and remove clutch plate and shims. (Scheme 7)
2. Remove pulley snap ring and tap pulley (with bearing) off of compressor. Remove screw for clutch coil lead. Remove snap ring and clutch coil.

To install, reverse removal procedure. Ensure pulley-to-clutch plate clearance is .016-.024" (.40-.60 mm). If clearance is incorrect, add or remove shim(s) as necessary.

1. Drain and measure compressor oil in compressor. Remove discharge valve body through-bolts. Remove discharge valve body bolts and body. Remove discharge valve plate and discharge valve.
2. Remove compressor through-bolts. Remove front and rear housing (oil separator case). Remove pins and gaskets. Remove shaft seal from shaft. Press shaft seal plate off of front housing (head cover).

To install components, reverse removal procedure. Tighten compressor through-bolts to 19 ft. lbs. (26 N.m). Tighten discharge valve bolts to 41 INCH lbs. (4.6 N.m). Tighten discharge valve body and body through-bolts to 96 INCH lbs. (10.8 N.m).

Scheme 7

NIPPONDENSO 6 & 10-CYLINDER

Note. Due to variety of clutch and shaft seal configurations, obtain appropriate A/C compressor service tools for compressor being serviced.

Removal (Honda)

Hold clutch plate stationary and remove shaft bolt. Remove clutch plate and shims. Remove snap ring and pulley. Remove snap ring and clutch coil. (Scheme 8)

To install, reverse removal procedure. Use NEW snap rings. Ensure snap rings are installed with beveled side facing out. Install clutch coil with wire facing downward. Apply thread lock to shaft bolt. Tighten shaft bolt to 10 ft. lbs. (14 N.m). Ensure air gap between clutch plate and pulley is .014-.026" (.35-.65 mm). If air gap is incorrect, add or remove shim(s) as necessary.

Note. On some models, compressor shaft seal is not serviceable. On some models, if shaft seal leak is large and/or refrigerant is leaking, replace compressor. On all models, a small amount of refrigerant oil leakage from compressor shaft seal is normal.

Removal (Lexus, Mitsubishi, Porsche & Toyota)

1. On Diamante Wagon, Lexus, Porsche and Toyota (except MR2), use a M8 x 40 mm bolt with 7/32" of the threaded end machined to a cone shape to remove clutch plate. On all other models, remove nut and clutch plate using Clutch Plate Holder/Remover (J-41384).
2. On all models, remove snap ring and shim(s) from shaft. Tap pulley off shaft with plastic hammer. If pulley cannot be removed by hand, use a puller. Remove snap ring, bearing, and seal (if equipped) from pulley. (Scheme 8)or (Scheme 11). Remove screw for clutch coil lead. Remove snap ring and clutch coil.

To install, reverse removal procedure. Ensure snap rings are installed with beveled side facing out. Tighten shaft bolt (or nut) to 14 ft. lbs. (19 N.m) on MR2; 11-15 ft. lbs. (15-20 N.m) on all others. Ensure air gap between clutch plate and pulley is .020" (.50 mm) on Diamante Wagon; .016-.028" (.41-.71 mm) on all others. If air gap is incorrect, add or remove shim(s) as necessary.

Note. On some compressors, it is necessary to use a dial indicator on clutch plate to check air gap. Energize clutch coil and zero dial indicator. De-energize clutch coil and measure air gap. Ensure air gap is as specified.

Scheme 8

Scheme 9

Scheme 10

Scheme 11

SHAFT SEAL

Note. On Chrysler, Mazda MPV, and Mitsubishi, remove compressor through-bolts and front housing to remove shaft seal. (Scheme 11) Alternately tighten through-bolts to 18-21 ft. lbs. (24-28 N.m).

1. Remove clutch plate and pulley. Remove shim(s) from shaft. Remove clutch coil if necessary. Remove felt and felt retainer (if equipped). (Scheme 8)or (Scheme 11). Place shaft key remover on shaft and turn to remove key.
2. Remove seal plate snap ring. Engage plate remover on seal plate, and pull up to remove seal plate. Engage shaft seal remover/installer to shaft seal, and pull up to remove shaft seal from front housing.

1. Apply clean refrigerant oil to compressor housing bore. Lubricate shaft seal with refrigerant oil and install in front housing. Lubricate seal plate and install in front housing.
2. Install shaft key, snap ring, felt retainer and felt. With clutch plate installed, ensure air gap between clutch plate and pulley is .020" (.50 mm) on Diamante Wagon; .014-.026" (.35-.65 mm) on all others. If air gap is incorrect, add or remove shim(s) as necessary.

Hold clutch disc stationary and remove shaft bolt. Remove clutch disc and shim(s) from shaft. Remove snap ring. Using a puller, remove pulley. Remove screw from clutch coil lead. Remove screws and field coil.

To install, reverse removal procedure. Ensure air gap is .016-.024" (.41-.61 mm). If air gap is incorrect, add or remove shim(s) as necessary. Tighten shaft bolt to 11 ft. lbs. (15 N.m).

Remove compressor head cover. Remove discharge valve stopper and discharge valve. (Scheme 12) Install replacement discharge valve and stopper. Tighten discharge valve bolts to 35-56 INCH lbs. (4.0-6.3 N.m). Tighten compressor head cover bolts to 79-104 INCH lbs. (8.9-11.7 N.m).

Scheme 12

Remove compressor rear cover. Remove oil control valve. Remove springs, valve, and rear cover seal. To install, reverse removal procedure. Tighten oil control valve bolts to 96-104 INCH lbs. (10.8-11.7 N.m). Tighten rear cover nuts to 22-25 ft. lbs. (30-34 N.m) and bolts to 113-156 INCH lbs. (12.8-17.6 N.m).

Remove clutch disc and shim(s). Remove felt seal and snap ring. Using Seal Plate Remover (49 B061 005), engage and remove shaft seal plate. Remove shaft seal with Seal Remover/Installer (49 B061 006). To install, reverse removal procedure. Coat new seal plate and seal with clean refrigerant oil. DO NOT touch seal surfaces with fingers.

CLUTCH COIL & SHAFT SEAL

Note. Due to variety of clutch and shaft seal configurations, obtain appropriate A/C compressor service tools for compressor being serviced.

Removal (Chrysler & Mitsubishi)

1. Remove drive belt pulley (if equipped). Hold clutch plate using Pliers (MB991367) and Bolts (MB991386). Use a ratchet and socket to remove clutch hub nut.
2. Remove clutch plate. (Scheme 13)or (Scheme 14). Remove snap ring with internal snap ring pliers. Remove clutch hub (rotor). Remove snap ring and clutch coil.
3. Using an awl, remove bearing cover and retainer. Using Bearing Remover (MB991456), engage bearing grooves. Place base of bearing remover over remover arms and tighten nut.
4. Tighten bearing remover bolt to withdraw bearing from compressor. Engage grooves of Shaft Seal Remover/Installer (MB991458) and pull straight up on shaft seal.

1. To install shaft seal, ensure front housing is free of foreign objects. Lubricate Shaft Seal Protector (MB991459) and place over compressor shaft. Lubricate shaft seal and install using shaft seal remover/installer. Remove shaft seal protector.
2. Using a 21-mm socket or Drift (MB991301), carefully press bearing onto compressor shaft. Install clutch coil so that alignment pin is engaged. Install clutch coil snap ring with tapered side facing out.
3. Align armature plate with crankshaft spline. Tighten shaft nut to 12 ft. lbs. (16 N.m). Using feeler gauge, ensure clearance between pressure plate and pulley is .016-.024" (0.4-0.6 mm). If clearance is incorrect, add or remove shim(s) as necessary.

1. Remove shaft nut while holding clutch plate with Clutch Holder (J-37872). Remove pressure plate and shim(s). Remove snap ring.
2. Using universal puller attached to outer diameter of pulley, and Driver (07947-6340300) in center of pulley, remove pulley. DO NOT engage puller on belt area. Hold puller in place and tighten screw to remove pulley. Remove screw for clutch coil lead. Remove snap ring and clutch coil.

1. To install, reverse removal procedure. Align lug on clutch coil with hole in compressor. Install snap ring with chamfered side facing out. Position pulley squarely over coil. Using Hub Guide (07945-6920500), press pulley onto compressor boss. Maximum press load is 5690 psi (400 kg/cm 2 ) or 882 lbs. (400 kg).
2. Tighten shaft nut to 13 ft. lbs. (18 N.m). Using feeler gauge, ensure clearance between pressure plate and pulley is .014-.026" (.35-.65 mm). If clearance is incorrect, add or remove shim(s) as necessary.

Note. If shaft seal leaks, replace compressor.

Scheme 13

Scheme 14

Removal (Jaguar)

1. Using 3 bolts, attach Puller (JD166-1) to clutch plate. While holding clutch plate with puller, remove shaft nut. Install puller bolt in center of puller, and tighten bolt to remove clutch plate.
2. Remove adjustment shim(s) and Woodruff key. Remove pulley snap ring. Install threaded Adapter (JD166-5), onto compressor shaft. Engage Collets (JD166-5) to inner diameter of pulley and attach Puller (JD166-1) to collets.
3. Install puller bolt in center of puller, and tighten bolt to remove pulley. Press bearing out of drive belt pulley. Remove screw for clutch coil lead. Remove snap ring and clutch coil.

To install clutch coil and bearing, reverse removal procedure. Tighten shaft nut. Ensure air gap is .016-.031" (.40-.80 mm). If air gap is incorrect, add or remove shim(s) as necessary.

Removal (Volkswagen)

Remove shaft nut while holding clutch plate with two 1/4" bolts and Spanner Wrench (Mastercool 90901). Remove clutch plate using two 1/4" bolts and Puller (Mastercool 90902). Remove lock ring. (Scheme 15) Using 2-jaw universal puller, remove drive belt pulley. Press out bearing out of drive belt pulley.

To install, reverse removal procedure. Using a depth gauge on drive belt pulley, measure distance to clutch plate to check air gap. Apply voltage to clutch coil and measure distance once again. Ensure air gap, difference between first and second measurement, is .028" (.70 mm). To adjust air gap, further tighten clutch plate nut.

Scheme 15

1. Using 3 bolts, attach Puller (JD166-1) to clutch plate. While holding clutch plate with puller, remove shaft nut. Install puller bolt in center of puller, and tighten bolt to remove clutch plate.
2. Remove Woodruff key, felt seal, and seal seat snap ring. Engage Seal Seat Remover/Installer (JD167) to seal seat, and remove seal seat. Engage Seal Remover/Installer (JD168) to shaft seal, and remove shaft seal.

Lubricate shaft seal protector and shaft seal with refrigerant oil. Using seal remover/installer, install shaft seal. Lubricate seal seat "O" ring with refrigerant oil, and install seal seat. To complete installation, reverse removal procedure.

Note. Shaft seal removal and installation procedure is not available from Volkswagen.

Saab and Volvo

Compressor servicing procedures not available at time of publication.

ZEXEL ROTARY VANE

Note. Subaru recommends replacing compressor as an assembly.

Removal (Honda, Isuzu & Kia)

1. Using clutch plate holder, remove clutch plate bolt. Using puller and forcing screw, remove clutch plate. (Scheme 16)
2. Remove shim(s) and snap ring. On DKS-17CH compressor, remove cover located under snap ring. On DKV-14D and DKS-17CH compressors, use pulley puller pilot. On all models, use a puller to remove pulley. Remove screw for clutch coil lead. Remove 3 screws and clutch coil.

1. To install, reverse removal procedure. Align and install clutch coil. Tighten clutch coil screws to 44 INCH lbs. (5 N.m). Using pulley installer and drive handle, tap pulley onto compressor. On DKS-17CH compressor, install cover located under snap ring. On all models, install new snap ring.
2. On DKS-17CH compressor, tighten clutch plate bolt to 11 ft. lbs. (15 N.m). On DKV-14D compressor, tighten clutch plate bolt to 113 INCH lbs. (13 N.m) Using feeler gauge, ensure clearance between clutch plate and pulley is .012-.024" (.30-.60 mm). If clearance is incorrect, add or remove shim(s) as necessary.

Kia

Shaft seal servicing procedure not available at time of publication.

Scheme 16

Removal (Infiniti & Nissan)

1. Hold clutch disc using Clutch Disc Wrench (J-38874) and remove center bolt. Using Clutch Disc Puller(J-38874), remove clutch disc and adjustment shim(s).
2. Remove snap ring. Remove pulley using Pilot (J-39023) and universal puller. Remove clutch coil. (Scheme 17)

1. Ensure coil lead is installed in original position. Install and tighten coil screws. Press pulley onto compressor using Pulley Installer (J-39024). Install snap ring and adjustment shim(s).
2. Install clutch disc and tighten center bolt to 11-13 ft. lbs. (15-18 N.m). Using feeler gauge, ensure clearance between clutch disc and pulley is .012-.024" (.30-.60 mm). If clearance is incorrect, add or remove shim(s) as necessary. Break-in clutch by engaging and disengaging clutch 30 times.

Nissan

Shaft seal servicing procedure not available at time of publication. Tighten thermal protector, if removed, to 11-13 ft. lbs. (15-18 N.m).

Scheme 17

Volvo

Zexel compressor servicing procedure not available at time of publication.

Note. Subaru recommends replacing compressor as an assembly.

Removal (Audi)

1. Using Spanner Wrench (44-4), hold clutch hub stationary and remove shaft bolt. Remove clutch plate and shim(s) using Puller (VAG 1719) and Spanner Wrench (3212). (Scheme 18) Remove snap ring.
2. Place Spacer (VAG 1719/1) in center of pulley cavity. Attach Puller (US 1078) to outer diameter of pulley and remove pulley. Remove snap ring, bearing, and clutch coil as necessary.

Ensure clutch coil lug fits into hole on compressor housing. Using Installer (VAG 1719/2), press on pulley and install snap ring. Install shim(s) and clutch plate. Tighten shaft bolt to 11 ft. lbs. (15 N.m). Using feeler gauge, ensure air gap between pulley and clutch disc is .012-.024" (.30-.60 mm). If clearance is incorrect, add or remove shim(s) as necessary.

Scheme 18

Removal (Honda & Isuzu)

1. Using Clutch Plate Holder (J-33939), remove clutch plate bolt. Using Puller (J-33944-A) and Forcing Screw (J-33944-4), remove clutch plate.
2. Remove shim(s), snap ring, and cover. Using Pulley Puller Pilot(J-38324), Pulley Puller (J-8433), and Pulley Puller Legs (J-24092), remove pulley. Remove screw for clutch coil lead. Remove 3 screws and clutch coil.

1. To install, reverse removal procedure. Using Pulley Installer and Handle (J-8092), tap pulley onto compressor. Install snap ring with bevel side facing out.
2. Tighten clutch plate bolt to 11 ft. lbs. (15 N.m). Using feeler gauge, ensure clearance between clutch plate and pulley is .012-.024" (.30-.60 mm). If clearance is incorrect, add or remove shim(s) as necessary.

Removal (Nissan)

1. Using Clutch Disc Wrench (J-37877), hold clutch hub stationary and remove shaft nut. Remove adjustment shim(s) and clutch disc using Clutch Disc Puller (J-26571-A).
2. Bend lock washer away from lock nut. (Scheme 19) Remove lock nut with Wrench (J-37882). Remove pulley by hand or, if difficult to remove, use Pilot (J-26720-A) and universal puller. Remove snap ring, bearing, and clutch coil as necessary.

1. To install, reverse removal procedure. Ensure key is installed in compressor shaft keyway. Tighten lock nut to 25-29 ft. lbs. (34-39 N.m). Bend lock washer against lock nut.
2. Install clutch disc and tighten shaft nut to 10-12 ft. lbs (14-16 N.m). Using feeler gauge, ensure air gap between pulley and clutch disc is .012-.024" (.30-.60 mm). If clearance is incorrect, add or remove shim(s) as necessary. Break-in compressor clutch assembly by engaging and disengaging clutch 30 times.

Scheme 19

1. Using Clutch Plate Holder (J-33939), remove clutch plate bolt. Using Puller (J-33944-A) and Forcing Screw (J-33944-4), remove clutch plate. Remove shim(s) and felt.
2. Using Shaft Seal Remover/Installer (J-33942-B), remove shaft seal cover. Remove shaft seal snap ring. Using shaft seal remover/installer, remove shaft seal.

1. Place Shaft Seal Guide (J-34614) over compressor shaft. (Scheme 20) Lubricate shaft seal guide and shaft seal with refrigerant oil. Using shaft seal remover/installer, install shaft seal. Install shaft seal cover, felt, and shim(s).
2. Tighten clutch plate bolt to 11 ft. lbs. (15 N.m). Using feeler gauge, ensure clearance between clutch plate and pulley is.012-.024" (.30-.60 mm). If clearance is incorrect, add or remove shim(s) as necessary.

Note. Shaft seal servicing procedure not available at time of publication.

Scheme 20

See also:
• CLUTCH COIL &