A/C - Does Not Cool/Compressor Clutch Not Engaging

SX4

Section Title: HVAC
TSB No. TS 01 09267

Division: Automotive
Category: Technical

SUBJECT:
A/C DOES NOT COOL: COMPRESSOR CLUTCH DOES NOT ENGAGE

MODEL(S):
SX4 (RW420)

YEAR:
2007

CONDITION:
Air conditioner does not cool. When diagnosed it is found the compressor clutch does not engage when power is applied.

CAUSE:
Open circuit in electromagnet.

CORRECTION:
If the electric clutch circuit is found to be open internally at the clutch assembly replace only the clutch assembly. The clutch is available separately from the compressor. It is not necessary to remove the refrigerant from the system to do this repair. Follow the below procedure to replace the clutch assembly.





PART(S) INFORMATION:





WARRANTY CLAIM INFORMATION

Compressor Clutch Replacement Procedure on Vehicle





1. Securely place the vehicle on a lift and raise the vehicle enough to access the right front under cover. Remove the under cover. (Optionally remove the right front wheel assembly.)





2. Release the tension from the serpentine belt and slide the belt off of the compressor pulley.





3. Disconnect the electrical connector to the clutch magnet and remove the four mounting bolts of the compressor.





4. At the right wheel well, move the compressor to an angle suitable to remove the front armature plate bolt. Rock the plate and pull to remove plate. Do not lose the shims (See step 11). A ratchet wrench and three point spanner is being used in this example.





5. With the compressor in the position shown, remove the circlip with a 45 degree angle circlip tool.





6. Rock the clutch pulley equally from both sides and work it off the compressor stationary shaft.





7. Using a straight circlip tool, remove the circlip from the clutch magnet and remove the magnet.





8. Re-install the new clutch magnet. Note the index marks. The dimple must be aligned in the compressor groove or the clutch will fail when first engaged.








9. Hold the compressor and magnet with your right hand and install the circlip with your left hand using a 45 degree angle circlip tool. Note circlip rounded side faces compressor.








10. Re-install the clutch pulley.

11. Insert the mounting bolt into the armature plate then place the shims onto the bolt before installing to compressor.

12. Install the plate to the compressor. Torque the bolt to 16 Nm (11.5 lb-ft).





13. Check the armature to clutch pulley gap with a feeler gauge. Rotate the armature plate and check at several points. The gap should within 0.3-0.5 mm (0.012-0.020 in.). If not within spec., remove the plate and install or remove the appropriate thickness shim(s).

14. Re-connect the electrical connector to the clutch magnet.

15. Re-mount the compressor to the engine. Torque the bolt to 25 Nm (18.0 lb-ft).

16. Lower the vehicle and test the A/C for operation. If OK re-install the under cover and right wheel assembly (if removed). Repair is complete.





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