Compressor Clutch: Service and Repair

REMOVAL
- When removing center bolt, hold clutch disc with clutch disc wrench.





- Remove the drive plate using Tool KV99232340.
Insert holder's three pins into the drive plate. Rotate the holder clockwise to hook it onto the plate. Then, tighten the center bolt to remove the drive plate.
When tightening the center bolt, insert a round bar (screwdriver, etc.) between two of the pins (as shown in the image) to prevent drive plate rotation. After removing the drive plate, remove the shims from either the drive shaft or the drive plate.





- Remove the snap ring using external snap ring pliers.





- Pulley removal
Use any commercially available pulley puller. Position the center of it on the end of the drive shaft and remove the pulley assembly.
For pressed pulleys:
To prevent deformation of the pulley groove, the puller claws should be hooked under (not into) the pulley groove.
For machine latched pulleys:
Align the pulley puller groove with the pulley groove and then remove the pulley assembly.
- Remove the field coil harness clip using a screwdriver.





- Remove the three field coil fixing screws and remove the field coil.





INSTALLATION
- Install the field coil.
- Be sure to align the coil's pin with the hole in the compressor's front head.
- Install the field coil harness clip using a screwdriver.





- Install the pulley assembly using the installer and a hand press, and then install the snap ring using snap ring pliers.





- Install the drive plate on the drive shaft, together with the original shim(s). Press the drive plate down by hand.





- Using the holder to prevent drive plate rotation, tighten the bolt to 12-15 Nm (1.2-1.5 Kg-m, 9-11 ft-lb) torque.
- After tightening the bolt, check that the pulley rotates smoothly.





- Check clearance around the entire periphery of clutch disc.

Disc-to-pulley clearance: 0.3-0.6 mm (0.012-0.024 in)

If the specified clearance is not obtained, replace adjusting spacer and readjust.

BREAK-IN OPERATION
When replacing compressor clutch assembly, always conduct the break-in operation. This is done by engaging and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.