Ogura Clutch

REMOVAL

IMPORTANT: These procedures are for theist design clutch (P/N 21030300) used on A/C compressor (P/N 21030811) which is used on 1991-1993 vehicles, and (P/N 21030859) used on 1994-1995 vehicles built before and including VIN SZ245874.

IMPORTANT: It is not necessary to discharge the A/C system to service the A/C compressor clutch.





1. Loosen belt tensioner and remove accessory drive belt from compressor clutch pulley

2. Disconnect A/C compressor clutch electrical connector.





3. Remove rear A/C compressor to engine bracket bolts.

4. Remove front A/C compressor to engine bracket bolts.





5. With A/C lines still attached, lift compressor upward and install one front bolt through front engine bracket top hole and bottom rear mounting ear of compressor. Tighten bolt so compressor is supported by the bracket.





6. Install the clutch remover SA9149AC-4 and remove the drive plate center bolt with a 10 mm deep socket.





7. Install drive plate holder sleeve into drive plate holder. Install drive plate removal bolt. While holding handle, tighten bolt to remove the drive plate.

IMPORTANT: Be careful not to lose the shims when removing drive plate from compressor shaft.





8. Using external snap ring pliers, remove the snap ring.

IMPORTANT: Do not remove pulley without using adapter. If compressor shaft is pressed on, compressor will be damaged.





9. Position the puller center SA9149AC-2 on the end of the compressor hub. Install the jaw puller on compressor pulley. Tighten the center bolt to remove pulley assembly.

IMPORTANT: Be sure to hook the puller jaws behind the pulley.

IMPORTANT: Be sure to note the position of the coil wire before removal.





10. Remove three coil screws.

IMPORTANT: To enable easier removal of the screws, lightly tap on the end of the screwdriver with a plastic hammer before removal.

11. Disconnect coil wire connector.

INSTALLATION

IMPORTANT: Install clutch coil in same position removed.





1. Install clutch coil in same position as removed.

Torque: 3.9-5.9 N.m (35-52 in-lbs)

2. Connect the coil wire to harness.





3. Install pulley installation bolt, drive plate installer SA9149AC-3 and thrust bearing assembly through the center of the pulley. Thread pulley installation bolt into the end of compressor shaft finger tight.





4. Tighten nut on pulley installation bolt finger tight to align pulley to compressor. While holding end of bolt, tighten nut until pulley bottoms out on compressor.

5. Loosen nut and remove pulley installation bolt.





6. Install the snap ring with the tapered side out using snap ring pliers.





7. Install drive plate holder on new drive plate.

8. Place thrust bearing on installation bolt. Insert installation bolt through drive plate.

9. Install same amount of shims as removed from old drive plate over end of the installation bolt.

10. Thread installation bolt into compressor shaft.

11. Slide the drive plate onto the splines of the compressor shaft.

IMPORTANT: Make sure splines are engaged by rotating drive plate back and forth before tightening nut.

12. While holding the end of the installation bolt, tighten nut to press drive plate onto compressor shaft. Tighten until drive plate bottoms.





13. Loosen installation bolt nut. Remove installation bolt.

14. Install center bolt. Torque bolt to specification.

Torque: 11.8-14.7 N.m (104-130 in-lbs)

NOTICE: After tightening the bolt, check to be sure that the pulley rotates smoothly by spinning it.





15. Check that the clutch clearance is between 0.3 and 0.5mm (0.01 and 0.02 in). If necessary, adjust the clearance by using shim(s) provided. Repeat steps 6 and 7 of compressor clutch removal. Then repeat steps 8 through 14 of Compressor Clutch Installation.





16. Remove front bracket-to-compressor bolt and position A/C compressor between brackets.

17. Install A/C compressor to front bracket with three bolts. Finger tighten bolts.

18. Install A/C compressor to rear bracket with three bolts. Tighten front and rear bolts.

Front bolts:
Torque: 49 N.m (36 ft-lbs)

Rear bolts:
Torque: 25 N.m (19 ft-lbs)





19. Connect A/C compressor clutch electrical connector.

20. Install accessory drive belt.

21. Start engine and engage A/C compressor 10-15 cycles to break in new clutch assembly. This will match drive plate and pulley surfaces.