1. |
If the compressor is marginally operable, run
the engine at idle speed, and let the air conditioning work for a
few minutes, then shut the engine
off. |
2. |
Disconnect the negative cable from the
battery. |
3. |
Recover the refrigerant with a
recovery/charging station. |
4. |
Loosen the drive
belt. |
5. |
Remove the nuts, then disconnect the suction
line(A) and discharge(B) line from the compressor.Plug or cap the
lines immediately after disconnecting them to avoid moisture and
dust contamination.

|
6. |
Disconnect the compressor clutch connector(A),
then remove the mounting bolts and the compressor(B).

|
7. |
Using a hexagon wrench(6mm) remove the bolts,
the manifold assembly(A) and the gasket(B) from the
compressor.

|
8. |
Install in the reverse order of removal, and
note these items.
A. |
If you're installing a new compressor,
drain all the refrigerant oil from the removed compressor, and
measure its volume, Subtract the volume of drained oil from
150ml the result is the amount of oil you should drain from
the new compressor (through the suction
fitting). |
B. |
Replace the O-rings with new ones at
each fitting, and apply a thin coat of refrigerant oil before
installing them. Be sure to use the right O-rings for R-134a
to avoid leakage. |
C. |
To avoid contamination, do not return
the oil to the container once dispensed, and never mix it with
other refrigerant oils. |
D. |
Immediately after using the oil, replace
the cap on the container and seal it to avoid moisture
absorption. |
E. |
Do not spill the refrigerant oil on the
vehicle; it may damage the paint; if the refrigerant oil
contacts the paint, wash it off
immediately. |
F. |
Adjust the drive
belt. |
G. |
Charge the system, and test its
performance. | |
1. |
Check the plated parts of the pressure plate
for color changes, peeling or other damage. If there is damage,
replace the clutch set. |
2. |
Check the pulley bearing play and drag by
rotating the pulley by hand. Replace the clutch set with a new one
if it is noisy or has excessive play/drag.

|
3. |
Measure the clearance between the pulley(A)
and the pressure plate(B) all the way around. If the clearance is
not within specified limits, remove the pressure plate and add or
remove shims as needed to increase or decrease
clearance.
Clearance : 0.5 ± 0.15mm (0.020 ± 0.006
in.)
|
The shims are available in seven
thicknesses : 0.7mm, 0.8mm, 0.9mm, 1.0mm, 1.1mm, 1.2mm and
1.3mm.

| |
4. |
Check operating of the magnetic
clutch.
Connect the compressor side terminals to the
battery (+) terminal and the ground battery (-) terminal to the
compressor body.
Check the magnetic clutch operating noise to
determine the condition.

|
1. |
Remove the center bolt(A) while holding the
pressure plate with a commercially available pressure plate bolt
remover(B); Special tool number 09977-2900.

|
2. |
Remove the pressure plate(A) and shim(B),
taking care not to lose the shims. If the clutch needs adjustment,
increase or decrease the number and thickness of shims as necessary,
then reinstall the pressure plate, and recheck its
clearance.

|
3. |
If you replacing the field coil, remove snap
ring(A) with snap ring pliers.
•
|
Be careful not to damage the
pulley(B) and compressor during
remove/installation. |
•
|
Once snap ring(A) is removed,
replace it with a new one.

| | |
4. |
Remove the screw from the field coil ground
terminal.
Remove the field coil(A) from the shaft with a
puller(B). Be careful not to damage the coil and
compressor.

|
5. |
Reassemble the compressor clutch in the
reverse order of disassembly, and note these items :
A. |
Install the field coil with the wire
side facing down, and align the boss on the coil with the hole
in the compressor. |
B. |
Clean the pulley and compressor sliding
surfaces with non-petroleum
solvent. |
C. |
Install new snap rings, and make sure
they are fully seated in the
groove. |
D. |
Make sure that the pulley turns smoothly
after it's reassembled. |
E. |
Route and clamp the wires properly or
they can be damaged by the
pulley. | | |