A/C clutch shim procedure for S60

Here’s the now famous DIY procedure to fix your air conditioning with a AC clutch shim, but for the Volvo P2 automobiles.

• 1999–2006 Volvo S80 (P23)
• 2001–2009 Volvo S60 (P24)
• 2001–2007 Volvo V70 (P26E)
• 2002–2007 Volvo XC70 (P26L)
• 2003–2014 Volvo XC90 SUV (P28)

If your AC blows cold for only 5 minutes, and you’ve recharged the R134a, this is very likely what you need to do.

I’ve confirmed that my AC clutch is not engaging properly and that it could be because of wear to the clutch plate . I’ve read several posts about shimming the clutch plate so that the gap is return to within spec. I’ve seen instructions posted for other Volvo’s but not for the S60. Does someone have instructions on how to do this for the S60, or at least instructions on how to remove the AC clutch pulley.

Calvin says:

“Kevin, why don’t you try the “gread clip” fix? At this point, what have you got to lose. It should only take you 15-20 minutes and won’t cost you anything at all. I did this successfuly with both S70 and V70 a couple of years ago. I don’t know for certain but I expect your 02 compressor is the same as my 00 V70.”

AC clutch shim procedure for S60

Replacing the magnetic clutch compressor

Removing the magnetic clutch

1. Slacken off the screw for the clutch plate. Use counterhold 9995596 .
2. Remove the clutch plate. Use puller 9995597
3. Keep the shims.
4. Remove the snap ring.
5. Pull off the pulley. Use puller 999 5598 and socket 999 5599 .
6. Remove the magnet coil.

Installing the magnetic clutch

1. Install a new magnet coil. Tighten to: 5 Nm.
2. Install a new pulley. Use puller 999 5598 and socket 999 5600
3. Note! Position the tools behind the compressor mountings.
4. Install the snap ring.
5. Install the shims.
6. Install the clutch plate.
7. Tighten the screw. Use counterhold 999 5596 .
8. Tighten to: 13Nm.

Checking the clearance

Check the clearance between the clutch plate and the pulley using feeler gauge:

• The clearance must be 0.3–0.5 mm
• 0.3 mm clearance all the way round
• 0.6 mm clearance must not be found at any point.
• Replace the shims if the clearance is not between the given values. The following dimensions are available:
• 0.2 mm
• 0.3 mm – 1.0 mm.

AC Clutch Fix Pictures

The following images are from Volvo and describe replacing the magnetic clutch compressor.

AC clutch s30543him procedure for S60

Last Updated on August 21, 2020