Repair procedures

Removal

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 (-) battery terminal.
3. Recover the refrigerant with a recovery/charging station.
4. Remove the engine room under cover by loosening the mounting clip (A) and bolts (B).




5. Separate the front portion of the front wheel guard from the wheel base.

6. Remove the engine room right side under cover.




7. Loosen the drive belt.

8. Remove the bolts, then disconnect the suction line and discharge line from the compressor.

NOTE:
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

9. Disconnect the compressor switch connector (A).




10. Remove the compressor by loosening the mounting bolts.






Installation

1. Make sure the compressor mounting bolt with the correct length is screwed in. Tighten the mounting bolts with the specified tightening order.

Tightening torque :
20.00 - 32.95 N.m(2.04 - 3.36 kgf.m, 14.75 - 24.30 lb-ft)




2. Install in the reverse order of removal.
A. If you install a new compressor, drain all the refrigerant oil from the removed compressor and measure its volume. Subtract the volume of drained oil from the original capacity. The result is the amount of oil compressor 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.

Inspection

1. Check the plated parts of the limiter & hub assembly (A) for color changes, peeling or other damage. If there is damage, replace the assembly.
2. Check the pulley (B) bearing play and drag by rotating the pulley by hand. Replace the pulley with a new one if it is noisy or has excessive play/drag.






Disassembly

1. Remove the engine room under cover by loosening the mounting clip (A) and bolts (B).




2. Separate the front portion of the front wheel guard from the wheel base.

3. Remove the engine room right side under cover.




4. Loosen the drive belt.

5. Remove the clutch bolt (A) while holding the pulley with a clutch bolt remover (09977-3R000).





Tightening torque :
10.0 - 15.0 N.m (1.02 - 1.53 kgf.m, 7.37 - 11.0 lb-ft)

6. Loosen the limiter bolts and then remove the limiter & hub assembly.




7. Remove the pulley (B) after removing the snap ring (A) with a snap ring plier.









NOTE:
- Be careful not to damage the pulley and compressor during disassembly/reassembly.
- Once the snap ring is removed, replace it with a new one.

8. Reassemble in the reverse order of disassembly.

NOTE:
- Clean the pulley and compressor sliding surfaces with non-petroleum solvent.
- Install a new snap ring, and make sure they are fully seated in the groove.
- Make sure that the pulley turns smoothly after reassembly.