Compressor Clutch: Service and Repair

REFRIGERANT LINES

Removal and Installation for Compressor Clutch


REMOVAL

1.Remove the compressor. Removal And Installation.





2.Remove the three rubber plugs (1) from the clutch disc (2). To ease removal, apply some light lubricant to the three rubber plugs (1).
NOTE:
The three rubber plug holes are used for attaching the suitable tool when removing and installing the center bolt.





3.Remove the center bolt by holding the clutch disc steady using a suitable tool (A).
4.Remove the clutch disc and shim(s).





5.Remove the snap ring using external snap ring pliers.





6.Remove the pulley assembly using suitable tool (A).

CAUTION:
To prevent deformation of the pulley groove, the puller claws should be hooked under (not into) the pulley groove.





7.Remove the magnet coil snap ring (A) using a suitable tool.
Then remove the magnet coil (1) from compressor shaft.

INSPECTION AFTER REMOVAL

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 the contact surface of the pulley shows signs of excessive grooving, replace the clutch disc and pulley. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before installation.
Coil
Check the magnet coil for a loose connection or cracked insulation.

INSTALLATION






1.Install the magnet coil.

CAUTION:
Be sure to align the magnet coil pin with the hole in the compressor front head.





2.Install the magnet coil (1) on compressor shaft with the snap ring (A) using suitable tool.





3.Install the pulley assembly using Tool and a wrench, and then install the snap ring using snap ring pliers.
Tool number:-(J-38873-A)
4.Install the clutch disc on the drive shaft, together with the original shim(s) using a suitable tool. Press the clutch disc down using Tool.





5.Install the center bolt using suitable tool (A).
Center bolt: 12 Nm (1.2 kg-m, 9 ft-lb).
- After tightening the center bolt to specification, check that the pulley rotates smoothly.





6.Install the three runner plugs (1) on the clutch disc (2). To ease installation apply some light lubricant to the three rubber plugs (1).

INSPECTION OF CLUTCH DISC TO PULLEY CLEARANCE






1.Check the clearance around the entire periphery of the clutch disc (1) and pulley (2) using a suitable tool (A).
Clutch disc to pulley clearance (B) : 0.3 - 0.6 mm (0.012 - 0.024 in)

- Measure the clearance for the type 1 compressor as shown.
2.If specified clearance is not obtained, replace compressor clutch.

BREAK-IN OPERATION

When replacing compressor clutch assembly, always conduct the break-in operation. This is done by engaging and disengaging the clutch about 30 times. Break-in operation raises the level of transmitted torque.