Compressor Clutch Coil: Service and Repair

REMOVAL PROCEDURE

TOOLS REQUIRED
^ J 39200 Digital Multimeter
^ J 41384 Clutch Plate Holder/Remover

IMPORTANT
^ Discharge and recover the A/C system refrigerant, and remove the compressor from the vehicle, before performing compressor repairs.
^ During service of the compressor, prevent dirt and other foreign material from getting on the compressor parts and into the system. Clean tools and a clean work area are essential for proper service. Keep the compressor and the parts clean at all times.
^ Clean all of the parts that you will reassemble with a suitable solvent, and air-dry the parts.
^ Use only lint-free cloths in order to wipe the parts.
^ Drain and discard the oil that remains in the compressor. Add 90 ml (3.0 fl oz) of new refrigerant oil when the repairs are complete.




1. Remove the compressor from the vehicle.
2. Remove the pressure plate nut and the washer from the drive shaft using the J 41384.
3. Remove the pressure plate from the drive shaft using the J 41384.
4. Remove the clutch pulley snap ring (1) and the shim. Use the appropriate snap ring pliers.

IMPORTANT: During removal, do not damage the clutch pulley.




5. Remove the clutch pulley from the compressor by tapping with a plastic hammer.




6. Remove 1 screw (2) and the clutch coil wire retainer.
7. Remove the clutch coil snap ring using the snap ring pliers.
8. Remove the clutch coil from the compressor.
9. Inspect the pressure plate for excessive wear and for scoring. Replace the pressure plate as necessary.
10. Inspect the clutch pulley for excessive wear and for scoring. Replace the clutch pulley as necessary.




11. Measure the clutch coil resistance using the J 39200. Replace the clutch coil if the resistance is not within specifications.

Clutch Coil Resistance
2.9-3.8 Ohms at 20°C (68°F).

INSTALLATION PROCEDURE

TOOLS REQUIRED
J 41384 Clutch Plate Holder/Remover




1. Install the clutch coil to the compressor. Secure the clutch coil with the snap ring using snap ring pliers.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the retainer of the clutch coil wire (3) to the compressor. Secure the retainer with the 1 screw (2).

Tighten
Tighten the screw to 2-2.5 N.m (17.1-22.12 lb in).




3. Install the clutch pulley to the compressor. Secure the clutch pulley with the snap ring (1) and with the shim.




4. Install the pressure plate (1) to the compressor drive shaft.
5. Adjust the clearance (2) between the clutch pulley (3) and the pressure plate. Replace the shim in order to obtain the proper clearance.

Pressure Plate-to-Pulley Clearance
0.35-0.65 mm (0.014-0.025 in).




6. Install the pressure plate washer and the nut to the compressor drive shaft using J 41384.

Tighten
Tighten the pressure plate nut to 15-20 N.m (10.8-15.2 lb ft).

7. Install the compressor to the vehicle.