Compressor Clutch: Service and Repair

A/C clutch, servicing

(Nippondenso compressor)






NOTE:
- Remove ribbed V-belt and install
- Before removing ribbed V- belt, mark its running direction.


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

1 - Bolt
- 15 Nm (11 ft lb)
- Removing, installing See Fig. 1
2 - Clutch disc
- Pulling off See Fig. 2
3 - Shims
- For adjusting the gap between clutch disc and belt pulley
- Size of gap: 0.3 to 0.6 mm
- Checking and adjusting gap See Fig. 4
4 - Circlip
- Always replace
- Install with flat side facing compressor
- Make sure circlip is correctly located in the groove
5 - Belt pulley
- Remove with commercial two or three arm puller
- Use care to make sure belt pulley is not damaged
6 - Circlip
- Always replace
- Install with flat side facing compressor
- Make sure circlip is correctly located in the groove
7 - Magnetic coil
- Installing See Fig. 3
- With overheat fuse installed (interrupts circuit when coil overheats, in case of excessive compressor load e.g. hard to turn)
- With current protection diode -J201- (reduces voltage peaks which may occur when A/C clutch is shutoff)
8 - Bolt
9 - A/C compressor (Nippondenso)


WARNING!
Do not re-use any fasteners that are worn or deformed in normal use. Many fasteners are designed to be used only once and become unreliable and may fail when used a second time. This includes, but is not limited to, nuts, bolts, washers, self-locking nuts or bolts, circlips and cotter pins. Always follow recommendations given in this publication. Always replace these fasteners with new parts.

Fig. 1 Removing and installing clutch plate bolt






- Tightening torque: 15 Nm (11 ft lb)


NOTE: Use commercially available strap wrench -A- with fabric band to counter hold clutch disc.

Fig. 2 Pulling off clutch disc






- Pry off carefully with screwdrivers.


NOTE: With a tight fitting clutch disc, use commercial two or three-arm puller.

Fig. 3 Installing magnetic coil






- Align tab -A- in recess -B-.

Fig. 4 Checking and adjusting gap






- Measure gap between belt pulley and clutch plate using depth gauge -C- at 3 points. This is measurement -1-.
- Apply 12 V DC to magnetic coil.
- Positive B+ voltage to single pin connector -A
- Ground (-) to A/C compressor housing -B-
- Measure gap again between pulley and clutch disc measured with gauge -C-. This is measurement -2-.
- Difference between two measurements -1- and -2- must be: 0.4 to 0.6 mm (0.016 to 0.024 in.)


NOTE:
- The gap must lie within tolerances around the entire circumference.
- Gap can also be measured with compressor installed.
- If gap dimension lies outside of the permissible range, remove clutch disc and adjust gap dimension by removing or inserting spacer.