Compressor Clutch: Service and Repair

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CLUTCH AND CLUTCH FIELD COIL REMOVAL/INSTALLATION - HYBRID










Removal

1. Remove the A/C compressor. See - Air Conditioning (A/C) Compressor Removal/Installation.






2. Remove the A/C clutch disc and hub nut.
a. Using the special tool, hold the A/C clutch disc and hub.

b. Remove the A/C clutch disc and hub nut.

3. Remove the A/C clutch disc and hub.

4. Remove the A/C compressor pulley snap ring.






5. Using the special tool, remove the A/C compressor pulley.

CAUTION: Do not use air tools. Damage to the A/C clutch pulley or A/C compressor may result.

6. Remove the A/C clutch field coil snap ring.






7. Remove the A/C clutch field coil.
a. Remove the thermal protection switch bolt and bracket.

b. Detach the thermal protection switch from the A/C compressor.

8. Remove the A/C clutch field coil and thermal protection switch assembly.

Installation


NOTE: NOTE: The A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub and a new A/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed.

1. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage.

- Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat.
- Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth.
- Inspect for roughness in the A/C compressor pulley bearing.

2. Clean the A/C clutch field coil and pulley mounting surfaces.

3. Apply a pea-sized drop of silicone sealant to the thermal protection switch socket in the A/C compressor housing.






4. Install the A/C clutch field coil.
a. Install the A/C clutch field coil.

b. Install the thermal protection switch and bracket.

c. Tighten the bolt to 6 Nm {0.6 kgf-m, 53 in-lbf}






5. Install the A/C compressor pulley.
a. Install the special tool.

b. Install the A/C compressor pulley.


NOTE: The A/C compressor pulley is a tight fit on the A/C compressor. It must be correctly aligned during installation.

6. Install the A/C compressor pulley snap ring with the bevel side out.

7. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening.

8. Install the A/C clutch disc and hub.






9. Using the special tool, install the A/C compressor clutch disc and hub nut.
a. Hold the A/C clutch disc and hub with the special tool.

b. Tighten the bolt to 26 Nm {2.6 kgf-m, 19 ft-lbf}






10. Measure and adjust the clutch air gap by removing or adding A/C clutch disc and hub spacers.

11. Install the A/C compressor. See - Air Conditioning (A/C) Compressor Removal/Installation.