-

Remove the gauges from the
compressor; do not back seat the
compressor shutoff valves.

FIGURE 10: RECOVERY STATION OPEN VALVES

PART 2
AC Clutch removal

1. Remove both AC compressor drive belts.

-

Unscrew the AC belt tensioner and
remove it from the vehicle (figure 11).

-

Slide belts off the compressor and
crankshaft pulleys (figure 12).

FIGURE 11: REMOVE BELT TENSIONER BOLT

Writer: mg

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Date

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Page

11.2018

11.2020

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FIGURE 12: REMOVED TENSIONER & BELTS

2. Using a large adjustable wrench to hold

the hexagonal part of the clutch rotor,
remove the central M12 clutch mounting
screw (figure 13).

FIGURE 13: REMOVE M12 BOLT

3. Screw extractor tool #680888 in the center

of the clutch (figure 14).
Do not use a standard M16 screws,
doing so may damage the shaft end
bore or threads for the M12 screw.

FIGURE 14: EXTRACTOR TOOL IN PLACE
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11.2018

11.2020

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4. Using a large adjustable wrench to hold

the hexagonal part of the clutch rotor,
screw the extractor tool to pull out the
clutch from the compressor shaft (figure
15).
Do not use an impact wrench

FIGURE 15: REMOVING THE CLUTCH

5. Remove the clutch coil from the

compressor
-

Disconnect the coil

-

Remove the four M8 mounting screws
using a long tip 6mm Allen hex socket
(figure 16).

-

Remove coil from compressor (figure
17).

FIGURE 16: COIL MOUNTING BOLTS

FIGURE 17: CLUTCH & COIL REMOVED

Writer: mg

Special Bulletin

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Date

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Page

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11.2020

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11(31)

PART 3
SEAL REPLACEMENT

FIGURE 18: BITZER COMPRESSOR FRONT COMPONENTS (USE THIS DRAWING FOR PART IDENTIFICATION)

FIGURE 19: BITZER COMPRESSOR SHAFT SEAL KIT COMPONENTS

Writer: mg

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Date

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Page

11.2018

11.2020

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12(31)

1. Remove the oil chamber (# 12) and the
overflow tube (# 13) from the compressor
by unscrewing the three M5 mounting
screws (# 14) (figure 21).
Oil chamber and tube may be partially
filled with compressor oil, dispose properly.
-

Discard oil chamber mounting screws
and O-ring (# 11) inside the chamber
(figure 20).

-

Clean the inside of the oil chamber.

FIGURE 20: REMOVING OIL CHAMBER SCREWS

FIGURE 21: REMOVING OIL CHAMBER

Writer: mg

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Date

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2. Drain the oil from the compressor.
-

Remove both left and right drain plugs
and dispose of the oil in a graduated
container (figure 22 & figure 23)

-

Note the amount of oil drained from the
compressor.

-

Clean the threads of both drain plugs
and apply a coat of PTFE pipe sealant
to the threads.

-

Clean the drain holes and reinstall the
drain plugs.

FIGURE 22: OIL DRAIN (1)

TORQUE: 15-17 lb-ft (20-23 Nm)

FIGURE 23: OIL DRAIN (2)

Writer: mg

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Date

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Release

Page

11.2018

11.2020

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14(31)

3. Remove the compressor front sealing
cover.
-

Remove the 8 screws holding the
cover to the compressor (figure 24)

-

Slide the cover out-of-the-way, taking
care not to nick or scratch the
compressor shaft (figure 25).

TIP: Screw two of the mounting screws in
the cover threaded holes to disengage the
cover from the compressor.

FIGURE 24: SEALING COVER REMOVAL

-

Discard both cover O-Rings (front and
rear, # 9 and 11).

-

Clean both front cover and compressor
mating surfaces and threads.

FIGURE 25: REMOVED SEALING COVER EXPOSING
SLIDING RING

Writer: mg

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4. Remove the stationary ring and O-Ring
inside the front part of the sealing cover (#
7 and 8).
-

Slide the stationary ring and O-Ring
assembly out of the cover (figure 26).

-

Discard stationary ring and O-Ring.

FIGURE 26: STATIONARY RING REMOVAL

5. Remove the compressor sliding ring (# 6).
-

Using a long 2.5mm hex wrench (Allen
T-handle), unscrew the two set screws
securing the sliding ring to the
compressor shaft.

-

Remove and discard the sliding ring
(and set screws) (figure 27).

FIGURE 27: SLIDING RING REMOVAL

6. Remove the bearing sealing plate from the
compressor (figure 28).
-

Pull the sealing plate off (# 3).

-

Remove and discard sealing plate ORing (# 5).

-

Clean the sealing
reassembly.

plate

prior

to

FIGURE 28: BEARING SEALING PLATE

Writer: mg

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Date

Expiration

Release

Page

11.2018

11.2020

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7. Replace the slit radial gasket ring located
behind the bearing sealing plate (# 4).
-

Remove and discard the old ring just
before the circlip # 2 (figure 29).

-

Slightly lubricate the new ring with
compressor oil.

-

Install the new ring in the groove of the
compressor shaft (figure 30).
FIGURE 29: RADIAL GASKET RING LOCATION

FIGURE 30: NEW RADIAL GASKET RING IN PLACE

8. Reinstall the bearing sealing plate on the
compressor (figure 31).
-

Install the O-Ring (#5) on the bearing
cover. Do not oil this O-Ring.

-

Slide back in place the sealing plate.

IMPORTANT: The bearing sealing plate
oil hole must be on top (12 O’clock
position).

FIGURE 31: BEARING SEALING PLATE O-RING & OIL HOLE
LOCATION

Writer: mg

Special Bulletin

9. Install the new
compressor shaft.
-

sliding

ring