Manual Air Conditioner

Removal and Installation for Compressor Clutch

REMOVAL
1. Remove the compressor. Refer to (QR25DE), "Removal and Installation for Compressor - VQ35DE Models" (VQ35DE).




2. Remove the center bolt by holding the clutch disc steady using Tool.
Tool number : (J-44614)

3. Remove the clutch disc.




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




5. Remove the pulley assembly using Tool.
- Use a pulley puller with a small adapter. Position the small adapter on the end of the compressor shaft and the center of the puller on the small adapter as shown.

Tool number : KV99233130 (J-29884)

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

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




7. Remove the magnet coil harness clip using a screwdriver.




8. Remove the three magnet coil screws and remove the magnet coil.

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 harness clip using a screwdriver.




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). Press the clutch disc down using the drive plate installer.




5. Install the center bolt using Tool.
Center bolt : 12 Nm (1.2 kg-m, 9 ft-lb).
Tool number : (J-44614)

- After tightening the center bolt to specification, check that the pulley rotates smoothly.

INSPECTION AFTER INSTALLATION




Check the clearance all the way around the clutch disc as shown.

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

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

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.