Compressor Clutch: Service and Repair

A/C Clutch -N25-, Servicing (Denso)







Special tools, workshop equipment, test and measuring appliances and auxiliary items required

Not illustrated:
- Torque wrench (5 - 50 Nm)
- Locally available two-arm puller (e.g. Kukko 20-10) with fixtures for a depth of 100 mm.
- Locally available strap wrench
- Depth gauge


NOTE:
- Refrigerant circuit does not need to be opened to service the A/C clutch.
- If unable to service A/C clutch on compressor installed in vehicle, discharge refrigerant and remove compressor from compressor bracket.


1 - Hex head combination bolt
- 15 Nm (11 ft lb)
- Removing and installing See Fig. 1
2 - Clutch plate
- Removing See Fig. 2
- Checking clutch plate gap See Fig. 4
3 - Shims
- Used to adjust gap between clutch plate and pulley
- Gap: 0.4 - 0.6 mm (0.015 - 0.023 in)
4 - Circlip
- Always replace
- Install correctly: Thick side faces compressor.
- Ensure correct seating in groove.
5 - Clutch pulley
- Remove with locally available 2 or 3 arm puller.
Ensure puller is seated correctly to prevent damage to pulley.
6 - Circlip
- Always replace
- Install correctly: Flat side faces compressor.
- Ensure correct seating in groove.
7 - Clutch coil
- Installing See Fig. 3


NOTE: A thermo-fuse is incorporated into the clutch coil. Current to the clutch coil is interrupted in the event of compressor overheating (e.g. a binding compressor).


8 - Screw
9 - Compressor
- Manufacturer: Denso

Fig. 1 Combination bolt for clutch plate, removing and installing







- Remove bolt.
- Tightening torque: 15 Nm (11 ft lb)

When removing and installing bolt, counterhold with locally available strap wrench -A-.

Fig. 2 Clutch plate, removing







- Pry off clutch plate carefully with two large screwdrivers.

Use locally available 2 or 3 arm puller if plate is securely seated (difficult to remove).

Fig. 3 Clutch coil, installing







- Install coil on compressor.
- Locate locking pin-A- in recess -B-.

Fig. 4 Clutch plate gap, checking







- Gap: 0.4 - 0.6 mm (0.015 - 0.023 in)


NOTE:
- In order to check gap with compressor installed in vehicle:
- Bring front end assembly (lock carrier) into service position.


Determine "Dimension 1"
- Using depth gauge -C-, measure gap between top of clutch plate and belt pulley at three equally spaced locations (measurement must not deviate).

Determine "Dimension 2"







- If compressor is installed in vehicle, disconnect compressor electrical connector -A- from vehicle wiring harness.
- Using a jumper wire, energize clutch coil by applying 12V to connector -A- (battery terminal B+). If compressor is removed from vehicle, compressor -B- must be grounded.
- With clutch energized, measure gap between belt pulley and clutch plate with depth gauge -C-:
The allowable gap (0.4 - 0.6 mm / 0.015 - 0.023 in) is the difference between "Dimension 1" and "Dimension 2".


NOTE:
- Gap must be within tolerance around entire circumference.
- If gap is outside the permitted tolerance range, remove clutch plate and adjust gap by adding or removing shims.