Compressor Clutch: Service and Repair

Compressor Clutch: Removal and Installation

Magnet Clutch Assembly






REMOVAL

1. Remove the compressor.
2. Remove the center bolt while holding the clutch disc stationary using Tool as shown.






Tool number : J-44614

3. Remove the clutch disc.
4. Remove the snap ring using external snap ring pliers or suitable tool.






5. Remove the pulley using Tool with a small adapter. Position the small adapter on the end of the drive shaft and the center of the puller on the small adapter.






Tool number : KV99233130 (J-29884)

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

6. Remove the magnet coil harness clip using a screwdriver, remove the three magnet coil fixing screws and remove the magnet 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 magnet coil for loose connections or any 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, then install the snap ring using snap ring pliers.






Tool number : - (J-38873-A)

4. Install the clutch disc on the compressor shaft, together with the original shim(s). Press the clutch disc down by hand.






5. Install the clutch pulley bolt using Tool, to prevent the clutch disc from turning and tighten the bolt to specification.






Tool number : J-44614

CAUTION: After tightening the clutch pulley bolt, check that the clutch pulley rotates smoothly.

6. Check the pulley 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)

7. If the specified clearance is not obtained, replace the adjusting spacer to readjust.
8. Install the compressor.

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.