Could you elaborate on how you replaced the clutch plate? Did you follow the procedure in the factory service manual and use the Mercedes puller tool? I'm going to attempt this soon, and would like to know as much as possible before I tackle it.

Speedy,

I didn't have access to FSM and for my unit the procedure really wasn't all that involved. Again, I did this on my '91 5-cylinder OM602 on a Denso 10PA15C. I see you have (2) OM603's and there is a little less room up front on the 603 comparatively speaking and I think the compressor is different as well.

Remove the fan clutch, fan shroud, belt, and PS pump pulley this will give you as much room as possible for an in situ replacement. My compressor had the 10mm bolt, I think yours may have a nut (my '87's have the Denso 10P15C compressor with the nut). Remove the fastener and the clutch plate will be free (I used an old strap style oil filter wrench as a counter hold), it is on a splined shaft and be aware there may be spacers. Here and now is where the challenge begins. There is a snap ring holding the pulley and bearing (one assembly in my case). Your really doing this by feel since visual access is very limited and a good pair of snap ring pliers is needed. Mine were straight and if I were to do it again, I would get a pair with a 90 degree bend. To remove the pulley/bearing I ever so lightly tapped around the pulley and the assembly came off. After removing the pulley/bearing assembly, I removed and unplugged all the electrics. The next challenge is another snap ring further back, remove this snap ring and the magnet will come off the compressor. Assembly is reverse order and again the most challenging aspect will be putting the snap rings back on working 'blind' so to speak.

I've attached a picture of the Denso compressors for reference. The reman A/C clutch kit I got from Phil was group 37 in this picture and was from MB.

- Mark

Attached Thumbnails

 

__________________
1987 300DT 127K
1987 300TDT 283K (Sold)
1999 528iTa 75K
1991 300D 2.5T 214K - Dead Tranny
1984 300DT 375K (Sold)

I am going to be changing my water pump.

How do u remove the fan in this car ?

Thanks.