A/C Compressor Clutch - Service Procedure
NUMBER: 10-40-85APPLICABILITY: MATSUSHITA A/C EQUIPPED VEHICLES DATE: 09-11-85
SUBJECT: COMPRESSOR CLUTCH SERVICE PROCEDURE
The compressor Clutch on Matsushita air conditioning compressors will become a serviceable item starting October 14, 1985.
COMPRESSOR CLUTCH:
Parts information and descriptions of the compressor and clutch are listed below in Figure 1.
Compressor Assembly (with clutch) - SOA 438A200
Compressor Assembly (without clutch) - SOA 438A320
Clutch Assembly (See A, Fig. 1) - SOA 438A322
Shim (0.2 mm) Quantity (2) - SOA 438A324
Shim (0.5 mm Quantity (2) - SOA 438A323
The clutch assembly (SOA 438A322, See A, Fig. 1) is supplied with the following parts:
1) 4 mm internal hex head M5x12 bolt 5) three M5x10 Phillips head screws
2) clutch hub 6) holding coil
3) snap ring 7) four (4) selective shims
4) pulley/bearing assy
Please be aware that two (2) 0.2 mm shims and two (2) 0.5 mm shims are included with both the clutch assembly (SOA 438A322) and the compressor assembly without clutch (SOA 438A320) for your convenience when servicing these items. These shims are also available separately, should they ever be needed.
Tools necessary for servicing the clutch include the following:
1) Pulley driver - Subaru Special Service Tool-P/N 926620000.
2) Compressor pulley puller (such as Kent Moore J-29884) or five (5) to six (6) inch universal gear puller (such as Kent-Moore J-25287).
3) External expanding snap ring pliers.
4) 4 mm external hex head socket.
5) Thickness (feeler) gauges with a range of 0.016-0.024 inches.
6) Torque wrench with a range capable of 31-87 in.lbs.
A supply of common hand tools will complete the necessary tool list.
The compressor must be removed from the vehicle to perform clutch service work. Make sure that the vehicle's battery is disconnected and that the system is discharged properly, then cap off the refrigerant lines and compressor openings, when opening the A/C system, to prevent dirt and moisture contamination and refrigerant oil loss. Remove the compressor from the vehicle using the procedure found in the applicable Subaru Service Manual.
FIGURE 2 - CLUTCH HUB:
Disassembly
(1) Temporarily install two (2) M5 bolts into the threaded holes in the clutch hub. Using a screwdriver or equivalent as a brace against these two bolts, unfasten the center bolt in the center of the clutch hub using a 4 mm external hex head wrench or socket. See Figure 2.
2) Pull the clutch hub off the compressor shaft making sure you do not lose the adjusting shims (usually 2).
FIGURE 3 - COMPRESSOR:
3) Use the snap ring pliers to remove the exposed snap ring located on the boss portion of the compressor. See Figure 3.
FIGURE 4 - PULLEY/BEARING ASSEMBLY:
4) Using a suitable pulley or gear puller tool, carefully remove the pulley/bearing assembly, taking care not to damage the compressor shaft threads. See Figure 4.
5) Disconnect the wiring to the holding coil and remove the three (3) Phillips head retaining screws. Remove the holding coil.
Inspection Check the friction surfaces of the clutch for damage due
to excessive heat or excessive grooving due to slippage. Oil or dirt on the friction surfaces should be cleaned with a non-oil based solvent such as spray brake cleaner.
Assembly 6) Install the holding coil onto the compressor as before,
routing the lead wire in the proper direction. Torque
for the three (3) retaining screws is 31-56 in.lbs.
FIGURE 5 - SNAP RING:
7) Apply a film of refrigerant oil on the boss portion of the compressor and place the pulley/bearing assembly onto the compressor, starting it squarely by hand. Place Subaru special service tool (P/N 926620000, pulley driver) onto the pulley/bearing assembly and tap with a hammer until the snap ring groove is fully exposed and the pulley/bearing assembly is fully seated. See Figure 5.
8) Reinstall snap ring.
9) Install the shims and the clutch hub. Hold the clutch hub firmly against the compressor shaft.
FIGURE 6 - CENTER SHAFT BOLT:
10) Using a thickness gauge, measure the hub to pulley clearance. This clearance should be 0.016-0.024 inches. If not within specifications, adjust using a combination of shims that provides the correct clearance. The center shaft bolt does not have to be installed during this clearance check. See Figure 6.
11) When the proper clearance is achieved, coat the center shaft bolt with non-hardening Loctite and install. Torque to 61-87 in.lbs.
12) Reconnect lead wires and reinstall compressor on the vehicle in the reverse order of disassembly. Recharge A/C system and check for normal operation.
Break-In - After the clutch assembly is replaced, it is necessary
to break in the friction surfaces properly. This may be accomplished by engaging and disengaging the clutch approximately thirty (30) times with the engine running.
The Flat Rate Operation Number and Time for clutch assembly R&R is as follows:
013-011 Compressor Clutch Assembly R&R (Including Compressor R&R) 1.1 hr.
010-101 Discharge, Evacuate and Charge A/C System 0.7 hr.
Applicable Failure Codes are as follows:
Compressor - PSB 15,17,25,46
Compressor Clutch - PSK 01,09,12,15,39