300tdi Aircon clutch wires repair

[steveG]

My wife was driving the D1 home last night and it decided to shred both the main belt and the A/C one.

She was only about 20 mins from home and I had spares in the car so we got a new main belt fitted, all the debris removed, and she drove home.

I've just gone out to fit a new aircon belt, and been greeted with this when I took the pulley cover off the compressor.

https://www.aulro.com/afvb/images/imported/2009/11/730.jpg

Seems when the belts have shredded the aircon one has run off the back of the compressor pulley and torn off the wires from the clutch.

I've never really taken much notice of what it looked like before it was mangled.
What are my chances of just soldering it back on, and is it possible to remove the whole clutch mechanism so I can have a decent go at it on the bench?

Steve

[steveG]

From what I can find out you cant remove the clutch unless you have a special puller to get it off, and installation tool to get it back on :-(

Is this something that the average auto-electrician would be likely to be able to do?

Alternatively, any suggestions on where to buy a puller to do it myself?

Steve

[justinc]

Steve,

I have nevwer had to use a puller with these, just remove circlip from memory and pull the clutch off. I have had success repairing these wires on many occasions, cutting back into the insulation reveals enough usually to solder to.

This cannot be done with Tdi Defender type Sanden compressors, only the Nippondenso Disco ones, as the Sanden compressors clutch isn't removable without degassing etc from memory.

JC

[steveG]

Thanks Justin - that's what I wanted to hear :)

I'm confident I can repair the wires once I get the clutch off and have some decent access.

Steve

[Bazzle218]

Just had a similar problem currentley on the road driving to Qld and was able to use a wire joiner as a quick fix until i get a chance t o solder it, Fyi

[steveG]

Well, it was easy to get off:
1. Remove the bolt holding the drive flange on
2. Remove circlip retaining the pulley
3. Remove circlip retaining the clutch solenoid.

The soleniod is just a sliding fit, but has a dowel to prevent it rotating.

Looks like its going to be a bit more difficult to solder back on than I thought. The belt has worn away about a third of the connector block. One wire has enough to solder to, the other I'm going to have to file away a bit more of the block to get somethign to solder onto:

https://www.aulro.com/afvb/images/imported/2009/11/720.jpg


Steve

[bblaze]

done a few jobs like that in my time and I try to build up around the new joint with a bit of epoxy or such like stuff, I believe it makes a more permanent job as it reduces the stress and vibration on the new joint
cheers
blaze

[steveG]

done a few jobs like that in my time and I try to build up around the new joint with a bit of epoxy or such like stuff, I believe it makes a more permanent job as it reduces the stress and vibration on the new joint
cheers
blaze

All back together now and working fine.

I didn't use epoxy, but I did put a decent blob of silicon around the new joint once it was all back together. Should do a reasonable job of supporting it. I managed to pick away around the broken contact and get a good solder joint so I'm pretty confident it will be OK.

Steve

[Jim.]

Hi all,

I did exactly the same thing with mine a couple of months ago, I removed the part and took it a good mate who can solder. After refitting I can't switch the a/c off, I tried reversing the wiring but it still ran on, I must have left something out when refitting: however I was really careful and thought I did it right:(

Can anyone help me out with this please?

Regards to all Jim.

[steveG]

Hi all,

I did exactly the same thing with mine a couple of months ago, I removed the part and took it a good mate who can solder. After refitting I can't switch the a/c off, I tried reversing the wiring but it still ran on, I must have left something out when refitting: however I was really careful and thought I did it right:(

Can anyone help me out with this please?

Regards to all Jim.

Does the compressor still run if you disconnect the plug?

Steve

[Jim.]

Hi Steve,

I havent tried disconnecting the plug, I'll give it a go today and let you this arvo:)

Thanks mate.

Regards to all Jim.

[roverrescue]

After having to do this repair twice. I have now protected the two wires by running them inside some brake bundy tube. 1 small 25mm piece for each wire, solded to a bracket which bolts onto the existing cable clamp.

Should protect them from the shredder if a belt lets go?

Steve

[steveG]

After having to do this repair twice. I have now protected the two wires by running them inside some brake bundy tube. 1 small 25mm piece for each wire, solded to a bracket which bolts onto the existing cable clamp.

Should protect them from the shredder if a belt lets go?

Steve

Sounds like a great idea Steve.

Also sounds like its not an uncommon occurrence.

I'm assuming that if the main belt goes it ends up amongst the aircon belt and derails it. Definitely on mine it was more that just a quick flick as the belt broke. The front of the aircon compressor is polished and the connector block on the clutch solenoid worn away so must have done a few rotations after coming off the pulley before it finally shredded.

Steve

[Bazzle218]

Have had a gander today. in preperation for doing the fix properly. For the life of me i can not see the circlip holding the clutch on. Is it under what looks like the rubber seal on the outside of the clutch. I dont want to stuff something thats going. I have a denso compressor and mine is a 1996 model. Perhaps i have a different compressor?

[steveG]

Hi Steve,

I havent tried disconnecting the plug, I'll give it a go today and let you this arvo:)

Thanks mate.

Regards to all Jim.

Having just pulled mine partially apart again, I think you may be missing a spacing washer in the compressor drive plate.
With the engine off, you should be able to turn the drive plate by hand which rotates the compressor. You will also see that there is a very slight gap between the drive plate and the pulley. This gap is set by washers that are inside the spline of the drive plate.

If you cant turn the compressor by hand and there is no gap you need to add washers/shims.

Maybe you had a washer fall out when you pulled it apart. Mine has at least one washer in there, and no washers under the head of the plate retaining bolt.

Steve

[steveG]

Have had a gander today. in preperation for doing the fix properly. For the life of me i can not see the circlip holding the clutch on. Is it under what looks like the rubber seal on the outside of the clutch. I dont want to stuff something thats going. I have a denso compressor and mine is a 1996 model. Perhaps i have a different compressor?

Hi Bazzle,
Mine is a 97 model with a Denso compressor.
Here is a photo of the circlip retaining the pulley after the drive plate is removed.


https://www.aulro.com/afvb/images/imported/2009/11/533.jpg

Once you remove the pulley there is another circlip - just a normal one not a frilly one like this - holding the solenoid/coil on.
Steve

[Jim.]

Hi all,

Just returned from a quick bushtrip (work related) I tell you what its getting pretty hot out there!!

I didn't have time to have a look the a/c during the week; however I think I might of lost the spacer you are talking about.........I can't spin the pully freely it's always tight.

I hope I can replace it without to much drama.

Regards to all Jim

[Bazzle218]

Just found this site. Has good instructions on removing and replacing AC clutch. Not sure how to post a link so I have just cut and pasted address.
Hope it is a help to other's:D


http://ww2.justanswer.com/uploads/SKeel1221/2009-07-06_171523_saturn_clutch_re.pdf

[Jim.]

Hi all,

I made a spacer out of a piece of flat metal, fitted it and a/c works perfectly now.

Thanks Jim

[Madana]

If you have any trouble with clutch I have sitting on the shelf which if you want it is yours. It came out of a Denso type comp which had the pulley damaged. Clutch physically looks good but havent tested

[eddy]

I have just been through the drama of having both belts shredding themselves,do not know which one went first,but both were fairly new Daycos.All bearings were renewed a couple of years ago,tensioner appears to run true,no noisy belts or other warning signs.
Of course when the air con belt went it ripped the clutch wires off the pulley.Have managed to solder them back together and the clutch works when wired direct to 12v,but not from the dashboard switch..I renewed the 30 amp fuse[which had blown]in the engine fusebox,the 60 amp fuse,also there, checked out ok.However there must be another fuse somewhere between the ac switch and the clutch relay.Anyone know where it is?

[TonyC]

I have just been through the drama of having both belts shredding themselves,do not know which one went first,but both were fairly new Daycos.All bearings were renewed a couple of years ago,tensioner appears to run true,no noisy belts or other warning signs.
Of course when the air con belt went it ripped the clutch wires off the pulley.Have managed to solder them back together and the clutch works when wired direct to 12v,but not from the dashboard switch..I renewed the 30 amp fuse[which had blown]in the engine fusebox,the 60 amp fuse,also there, checked out ok.However there must be another fuse somewhere between the ac switch and the clutch relay.Anyone know where it is?

Hi Eddy

What's the vehicle /engine?
My 95 Defender has fuses and relays for the air con with the batteries under the passenger seat.

Tony

[eddy]

The vehicle is a 1998 300TDI Auto Discovery.Looking at the wiring diagram it looks as if the 25 amp F6 fuse is involved in the ac circuit,it checked out as ok.Must be another fuse somewhere!

[sandman]

old thread, sorry to dredge up the past, did you manage to find a mysterious missing fuse Eddy? I've got a similar issue here....

[eddy]

Testing the memory,I think the problem was not a fuse,but both electric fans not working, preventing power to the ac clutch.They are Denso fans,so replaced them with Toyota fan motors from the wreckers.Took a bit of scratching around,had to swap mounts , fan blades and plugs to suit the Discovery.Hope this helps.