A/C Compressor Pulley And Clutch - Replacing
SECTION
8
GROUP
87
NO.
214
1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 39
DATE
Jan. 1998
RE:
Supplement to Service Manual Section 8(87) Replacing pulley and magnetic clutch 200 1975-1993
REFERENCE:
TP 31120/1, SECTION 8(82-88) BODY FITTINGS, INTERIOR, HEATING AND AC; 200 1975-19..
SPECIAL TOOL BULLETIN NO. 103.
Replacing pulley and magnetic clutch on A/C compressors Supplement to Service Manual Section 8(87)
This Service Bulletin describes the method for replacing the pulley and magnetic clutch on compressors. The tools used in this method are new.
Tools: P/N:
Torque wrench
Circlip ring pliers
Puller (compressor pulley/clutch) 9995598-1
Socket with ring (compressor pulley/clutch) 9995599-9
Socket with ring (compressor pulley/clutch) 9995600-5
Socket (compressor clutch plate) 9995601-3
Tool kit for replacing shaft seal 9995602-1
Socket with ring (compressor pulley/clutch) 9995618-7
Socket with ring (compressor pulley/clutch) 9995619-5
The above tools can be found in:
Special Tool Bulletin no. 103
Preparations/Method
1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 40
- Make note of radio code.
- Disconnect battery lead.
- Remove air cleaner assembly (see illustration).
- Fold back preheating hose.
1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 41
Slacken off the bell tensioner nuts.
Remove:
- drive belt
- diode nut and screw (3).
Separate switch (2).
Only applies to diesel engines
Remove compressor mounting screws.
1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 42
Remove the lower radiator hose from the mounting on the member.
Lift off the compressor and carefully hang it from the radiator hose mounting.
Applies to gasoline and diesel engines
Raise the car.
Remove splash guard under engine.
Replacing Pulley/Clutch
1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 43
Removing clutch plate.
Remove screw and washer.
Use counterhold 999 5596-5.
Remove the clutch plate.
Use puller 999 5597-3.
Note position of the tool.
Keep the shims.
Removing pulley.
Remove circlip.
1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 44
Remove pulley.
Use puller 999 5598-1 and sleeve 999 5599-3 (or 999 5618-7).
Note position of the tools.
Removing magnet coil.
Remove:
- circlip
- magnet coil.
Installing magnet coil
Install:
- magnet coil
- circlip.
Installing pulley
1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 45
Install:
- pulley loosely
- pulley using the tools: puller 999 5598-1 and sleeve 999 5599-3 (or 999 5618-7).
Note position of the tools.
Reinstall circlip.
Installing clutch plate
Install:
- shims. Ensure that the shims are reinstalled on the shaft in the same order as they were removed.
- clutch plate on compressor shaft, if necessary use puller 999 5598-1 ans sleeve 9995601-3.
- screw and washer or nut.
1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 46
Tighten to 15 Nm (11 ft. lbs).
Use counterhold 999 5596-5.
Check Clearance/Finishing Work
Run a feeler gauge all the way around in the gap. Clearance should be between 0.3 and 0.5 mm. 0.3 mm should pass all around the gap.
If the clearance is not between the given values, use shims to adjust clearance until it does.
Shims are available in the following dimensions:
^ 0.2 mm
^ 0.3 mm
^ 1.0 mm
Work after checking clearance
Install diode.
Connect connector.
Install:
- compressor (diesel)
1982 Volvo 240 L4-2127cc 2.1L SOHC B21F Copyright ? 2013, ALLDATA 10.52SS Page 47
- splash guard under engine
Lower the car.
Reinstall drive belt.
Tension drive belt and tighten the compressor.
Install:
- air cleaner (ACL) assembly
- preheating hose
- battery lead
Reset the clock and enter anti-theft radio code.
Function check
Operation No. Labor description Time
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