Compressor Clutch: Service and Repair

NOTE: The manufacturer "Nippon denso" has changed its name to "Denso."

CAUTION! DO NOT open the A/C refrigerant system to service the A/C clutch. Instead remove the compressor from the mounting bracket.

NOTE: See Removing and installing ribbed belt.

CAUTION! Before removing ribbed belt, mark the running direction. The belt could break if allowed to run in the reverse direction.

1 - Bolt
- 15 Nm(11 ft. lb)
- Removing and installing See Fig. 1.
2 - Clutch plate
- Removing See Fig. 2.
3 - Shims
- For adjusting gap between clutch plate and belt pulley
- Gap: 0.4-0.6 mm (0.016-0.024 in.)
- Checking and adjusting gap See Fig. 4.
4 - Circlip
- Always replace
- Must be installed correctly (flat side toward compressor)
- Must be properly seated in groove
5 - Belt pulley

NOTE: If belt pulley is installed too tight, use a commercially available two-arm or three-arm puller (for example) to remove. Make sure not to damage the belt pulley

6 - Circlip
- Always replace
- Must be installed correctly (flat side toward compressor)
- Must be properly seated in groove
7 - Magnetic coil
- Installing See Fig. 3.
- Installed with a fuse which interrupts the operation of the coil if it becomes too hot (e.g. if the compressor is not moving freely).
- Contains the protection diode - J201- for suppressing the voltage peaks which may occur when the A/C clutch is switched off.
8 - Bolt
9 - Compressor (Denso)


Fig. 1 Removing and installing clutch plate bolt





Tightening torque: 15 Nm (11 ft. lb)

NOTE: Use commercially available strap wrench -A- (with fabric strap for counterholding the clutch plate).


Fig. 2 Removing clutch plate





- Pry off carefully using screwdrivers.

NOTE: If the clutch plate is installed too tightly use a commercially available two-arm or three-arm puller to remove the clutch plate.


Fig. 3 Installing magnetic coil





- Locate tab -A- in recess -B-.


Fig. 4 Checking and adjusting gap





Gap width = difference between distance "1 " and distance "2" measured as follows:
- Measure distance "1" between belt pulley and clutch plate using depth gauge -C- (at three different points).

Apply 12 V to magnetic coil:
- B+ terminal to single-pin connector -A-
- Ground (GND) to compressor housing -B-

- Measure distance "2" between belt pulley and clutch plate using depth gauge -C-.

Gap width (distance "1" - distance "2") must be 0.4-0.6 mm (0.016-0.024 in.).

NOTES:
- The gap width must be within the tolerances around the whole circumference.
- The gap width can also be measured without removing the compressor (compressor installed).
- If the gap width is outside the specified tolerance, remove the clutch plate and adjust the gap width by removing or adding shims.