Compressor Clutch: Service and Repair

REMOVAL




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




- Remove the drive plate using the clutch disc puller.
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.
While tightening the center bolt, insert a round bar (screwdriver, etc.) between two of the pins (as shown in the figure) 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 a commercially available pulley puller. Position the center of the puller on the end of the drive shaft. Remove the pulley assembly with the puller.
For Pressed Pulleys:
To prevent deformation of the pulley groove, the puller claws should be hooked under (not into) the pulley groove.




- Remove the field coil harness clip using a screwdriver.
- Remove the three field coil fixing screws and remove the field coil.

INSPECTION




Clutch disc
If the contact surface shows signs of damage due to excessive heat, replace clutch disc and pulley.

Pulley
Check the appearance of the pulley assembly. If contact surface of pulley shows signs of excessive grooving, replace clutch disc and pulley. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation.

Coil
Check coil for loose connection or cracked insulation.

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 to 15 Nm (1.2 to 1.5 kg.m, 9 to 11 ft.lb) torque.
- After tightening the bolt, check that the pulley rotates smoothly.




- Check clearance all the way around the 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 recheck.

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.