Hello,

Before Repairing / Replacing the Clutch: Please check the following;

a. Make sure your Electric Fan is functioning properly and there is sufficient airflow through the condenser. b. Diagnose your (FCM) Fan control module.
c. Make sure you are getting 13.6 volt to the electromagnetic coil. b. Make sure your AC system is not overcharged with refrigerant. Insufficient air flow through the condenser, overcharged system, or low voltage is causing excessive heat. The electromagnetic coil is design to fail with excessive heat, to protect the compressor and the system for further Damages. (This coil is design with internal thermal breaker and with excessive heat the breaker will break the circuit after a while.)

Here are the clutch Repair / Replacement instructions, for SD7V16

Disassembling
a. Center Nut. (With belt and with electromagnetic coil)
1 2 3 Turn on the main switch (do NOT start the engine). Activate the compressor Clutch by asking for A/C. Remove the Nut Of the compressor Shaft (14 mm)

b. Center Nut. (Without using the belt)

1 Find best way to hold the Hub STILL (front Plate) by using a screwdriver and remove the center nut.

c. Hub (front Plate)

1. Just lift the hub with your bare hand. If the hub is stuck, lift it with 2 thin screwdrivers (opposite sides) and pry it gently. If the hub do not come off contact me for assistance. 2. Remove the shims (washers) off the shaft.

d. Pulley
1. Remove the Snap ring that holds the pulley (bearing) on the compressor nose. 2. Remove the pulley trying different ways: a. Just pull it with your bare hand b. Pry it with 2 large screwdrivers. (One on each side of pulley). c. Tap it gently using a small hummer. d. Use 2 or 3 jaw pulley puller.

Protect the shaft by a socket leaning on the compressor Nose. Do not lean the socket on the shaft seal. (You can rent a pulley puller in any parts store if you do not have one)

e. Coil (electromagnet)
1. Disconnect the Coil from the power source. 2. Remove the Snap ring that holds the Coil on the compressor front head. 3. Remove the Coil trying different ways: a. By pulling the coil with your bare hand. b. Pry it with a screwdriver all way around.

Assembling
In case you purchase a clutch repair KIT and you need to replace the Pulley bearing please see as last paragraph Bearing Replacement Instructions. Before you start installing all new parts I recommend you to clean the front head of the compressor. You can do it by wiping out the dust with a wet rug.

a. Coil (electromagnet)
1. Place the coil on the front head of the compressor. You will find on the bottom of the coil a guiding indentation (tit, bump). This indentation will Guide you to place the coil at the right position. You must choose the right direction (toward the power source). 2. Install the Snap ring that holds the Coil on the compressor front head. Make sure the ring snaps in his place. 3. Connect the Coil to the power source. Use the old OEM connector by soldering it to the pigtail, or by using by electric splicers you can find in any parts store. 4. Turn on the main switch (do NOT start the engine). Activate the compressor Clutch by asking for A/C. Place any Steel item on the coil to check if the coil works. 2. If the coil doesnt not function, check and replace the right fuse. NOTE: newer models are designed in a way that without the engine running you will not have power to the clutch.

b. Pulley
1. Place the pulley on the compressor nose and push it in trying different ways: a. Use a sleeve, the size of the inner race of the bearing, and tap the sleeve with a hummer. b. By pushing the pulley with your bare hand. c. Tap it gently using a small hummer on the inner part of the Pulley. 2. Install the Snap ring that holds the pulley (bearing) on the compressor nose. Make sure the ring snaps in his place.

c. Hub (front Plate)

You need to create the right gap so the hub will engage correctly. The smaller the gap, the longer the life of the clutch. But the hub is not allowed to touch the pulley when its not engaged.

1. 2. 3. 4.

The gap supposes to be 0.015-20. Since this clutch is design in a way that you cant slide a filler gauge between the hub and the pulley do it the following way: Install all shims (washers) on the shaft. Install the hub. Start to remove one shim at a time until the hub touches the pulley. Then add one shim only. Spin the pulley and make sure the hub is not touching the pulley.

d. Center Nut.
1. Turn on the main switch (do NOT start the engine). (The belt must be on) 2. Activate the compressor Clutch by asking for A/C. 3. Install the Nut on the compressor Shaft and tighten it (14 mm)

Bearing Replacement Instructions.

To remove the bearing out of the pulley is not easy but possible. The hardest part is to find the right tools (round metal). Not to bend the pulley you need to support it correctly. a. Support the Pulley where the machine stakes (tabs) are. b. Place on the top a strong round piece of metal (large Socket) the size slightly smaller than the opening in the pulley. c. Press the Bearing out with a press. To press the new bearing in: a. Support the pulley in the center of the Pulley. b. You can use the outer race of the old bearing as a tool to push the new bearing in. c. Make few new stakes with a center punch. Be careful. If the center punch slips you will damage the new bearing. Work safely, have fun, and stay cool. Adam