Repair Procedures

Removal

1. If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few minutes, then shut the engine off.
2. Disconnect the negative cable from the battery.
3. Recover the refrigerant with a recovery/charging station.
4. Remove the RH front tire.

5. Remove the engine room RH side under cover.

6. Separate the front portion of the front wheel guard (A) from the wheel house.




7. Loosen the drive belt.

8. Disconnect the suction line (A) and discharge line (B) from the compressor.





NOTE:
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

9. Disconnect the compressor switch connector (A).




10. Remove the compressor by loosening the mounting bolts.






Installation

1. Make sure of the length of compressor mounting bolts, and then tighten it with the specified tightening order.

Tightening torque :
22 - 33 N.m (2.04 - 3.36 kgf.m, 14.8 - 24.3 lb-ft)




2. Install in the reverse order of removal.
A. If you install a new compressor, drain all the refrigerant oil from the removed compressor and measure its volume. Subtract the volume of drained oil from the original compressor oil capacity (120 cc). The result is the amount of oil you should drain from the new compressor (through the suction fitting)
B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for R-134a to avoid leakage.
C. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils.
D. Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption.

Inspection

1. Check the plated parts of the disc & hub assembly (A) for color changes, peeling or other damage. If there is damage, replace the clutch set.
2. Check the pulley (B) bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one if it is noisy or has excessive play/drag.




3. Check operation of the magnetic clutch.
Connect the compressor side terminals to the battery (+) terminal and the ground battery (-) terminal to the compressor body. Check the magnetic clutch operating noise to determine the condition.






Disassembly

1. Remove the RH front tire.

2. Remove the engine room RH side under cover.

3. Separate the front portion of the front wheel guard (A) from the wheel house.




4. Loosen the drive belt.

5. Remove the center bolt (A) and the hub bolts (B) while holding the pulley with a disc & hub assembly bolt remover (09977-25100).

Tightening torque :
15 - 21 N.m (1.5 - 2.1 kgf.m, 11.1 - 15.5 lb-ft)




6. Remove the hub assembly (A) and shim (gap washer) (B), taking care not to lose the shim.




7. Remove the pulley (B) after removing the snap ring (A) with snap ring pliers.

NOTE:
- Be careful not to damage the pulley and compressor during disassembly/reassembly.
- Once snap ring is removed, replace it with a new one.








8. Reassembly is the reverse order of disassembly.

NOTE:
- Clean the pulley and compressor sliding surfaces with non-petroleum solvent.
- Install new snap ring, and make sure they are fully seated in the groove.
- Make sure that the pulley turns smoothly after reassembly.