20860349 Volvo.Penta Lock washer

START BY:a. remove air conditioning compressor 1. Disconnect negative wire (3) from the terminal on the compressor.2. Remove plates (1) and (2) from the compressor. 3. Put tool (A) in a vise, and fasten the compressor to it as shown.4. Remove screws (4) and dust cover (5) from the drive plate. 5. Use the 5P7417 Wrench (6) from tooling (B) to hold the drive plate while the nut is removed from the compressor shaft. 6. Install the 5P7415 Puller (7) from tooling (B) on the drive plate. Be sure the puller is fully engaged in the drive plate. Use puller (7) to pull drive plate (8) off the compressor shaft. Remove the key from the drive plate. 7. Use a screwdriver to remove shield (9) [part of the bearing shield assembly] from the pulley. 8. Use a screwdriver to remove the remainder of bearing shield (10) from the pulley. 9. Use the 1P1863 External Retaining Ring Pliers (11) from tooling (B) to remove snap ring (12) from the shaft for the pulley. 10. Use the 5P7411 Pulley Puller Group (13) and the 5P7394 Puller Adapter (14) both from tooling (B) to pull the clutch and pulley assembly off the shaft. 11. Use the 5P7384 Pulley Bearing Remover and 5P7400 Driver Handle (15) both from tooling (B) to remove the bearing from clutch and pulley assembly (16).Install Compressor Clutch And Pulley
Do not use the inner race to install the bearing. The bearing must turn freely after it is installed.
1. Clean the new bearing. Use 5P7400 Driver Handle (1) and 5P7388 Bearing And Pulley Installer (2) from tooling (B) to install bearing (3) in the clutch and pulley assembly. 2. Use the 5P7400 Driver Handle (1) and the 5P7388 Bearing And Pulley Installer (2) from tooling (B) to install clutch and pulley assembly (4) on the compressor. 3. Use the 1P1863 External Retaining Ring Pliers (5) to install retainer ring (6). The flat surface of the ring must be toward the bearing.
It is very important to keep all foreign material out of the bearing and the area below the bearing. DO NOT use air pressure.
4. Thoroughly clean the top of the clutch and pulley assembly and the area of the bore for the shield assembly.5. Install a new bearing shield retainer (8) with driver handle (1) and 5P7418 Dust Shield Retainer Installer (7). 6. Use 5P7416 Shield Installer (9) and the 5P7411 Pulley Puller Group both from tooling (B) to install a new shield (10).
When the drive plate is ready for installation, clean the friction surfaces of the drive plate and the clutch and pulley assembly. DO NOT use any lubricant.
7. Install square key (11) in the groove in drive plate (12).
Never use a hammer to install the drive plate. The compressor is easily damaged.
8. Put the groove on the compressor shaft in alignment with the key in the drive plate. Install the drive plate. 9. Use 5P7423 Hub and Drive Plate Installer (13) from tooling (B) to install drive plate (12) onto the shaft until there is approximately 2.38 mm (.094 in.) clearance between the friction surfaces of the drive plate and clutch and pulley assembly (4). 10. Install a new nut on the compressor shaft. Use 5P7417 Clutch Hub Holding Wrench (14) to hold the drive plate while the nut on the compressor shaft is tightened to a torque of 19 to 22 N m (14 to 16 lb.ft.). 11. Use a feeler gauge (15) to check the clearance between the friction surfaces of the drive plate and clutch and pulley assembly. The clearance must now be 0.56 to 1.45 mm (.022 to .057 in.). The clutch and pulley assembly must turn freely. 12. Put dust cover (16) in position on the drive plate, and install the screws that hold it in place. 13. Install plate (17) on the compressor as shown. Install plate (18) and negative wire (19) on the compressor as shown. Connect the wire to the terminal on the clutch coil.14. Install the air conditioning compressor. See Install Air Conditioning Compressor.15. Start the engine and operate the air conditioning system. Turn the unit off and on at least twenty times at approximately one second intervals. This will let the clutch and pulley assembly engage the drive plate correctly during normal operation.