Service Procedure For Retrofitted A/C Systems (ITB94-054)

Publication date: 1994-09-26
Reference number: ITB94-054

SERVICE PROCEDURE FOR RETROFITTED A/C SYSTEMS

TECHNICAL SERVICE BULLETIN

Reference Number(s): ITB94-054, Date of Issue: September 26, 1994

SERVICE PROCEDURE FOR RETROFITTED A/C SYSTEMS

Model(s): All Infinity Models Equipped With a Retrofitted A/C System

Classification: HA94-006

Section: Air Conditioning

Bulletin No.: ITB94-054

Date: September 26, 1994

BULLETIN ILLUSTRATION LIST

Fig 1: Typical Retrofit A/C System Replacement Parts

Fig 2: Identification for Vehicles with Retrofit A/C System

Fig 3: Connecting Tubes with Torque Wrench & Back-Up Wrench

Fig 4: Plugging Tube Ends

Fig 5: Lubricant Oil Application Area and O-ring Position

Fig 6: Tube/Union Connections

Fig 7: Checking for Leaks at Connections

Fig 8: HFC-134a Refrigerant

Fig 9: Nissan A/C System Oil

Fig 10: Recovery/Recycling/Recharging Equipment

Fig 11: Electrical Leak Detector

Fig 12: Manifold Gauge Set

Fig 13: Service Hoses

Fig 14: Service Couplers

Fig 15: Refrigerant Weight Scale

Fig 16: Vacuum Pump

Fig 17: Vacuum Pump (With and Without Isolator Valve)

Fig 18: Manifold Gauge Set

Fig 19: Service Hoses with Markings and Fittings

Fig 20: Service Hose Shut-Off Valve

Fig 21: Using Refrigerant Weight Scale

Fig 22: Gauge Shows High & Low-Pressure Sides Are Too High

Fig 23: Gauge Shows High Side Too High, Low Side Too Low

Fig 24: Gauge Shows High Side Too Low, Low Side Too High

Fig 25: Gauge Shows Both High and Low Sides Too Low

Fig 26: Low Pressure Side Sometimes Becomes Negative

Fig 27: Low Pressure Side Becomes Negative

Fig 28: Discharging Refrigerant

Fig 29: Charging A/C System

Fig 30: Oil Adjusting Procedure for Compressor Replacement

Fig 31: A/C Component Layout

Fig 32: Harness Layout

Fig 33: Wiring Diagram

Fig 34: Wiring Diagram (Cont'd)

Fig 35: Circuit Diagram for Quick Pinpoint Check

Fig 36: Checking Power Supply for Compressor

Fig 37: Checking Circuit Continuity

Fig 38: Checking Power Supply for A/C Relay

Fig 39: Checking Dual-Pressure Switch Circuit

Fig 40: Checking Circuit Continuity

Fig 41: Checking Coil Side Circuit of A/C Relay

Fig 42: Checking Circuit Continuity

Fig 43: Checking A/C Signal Relay Circuit

Fig 44: Checking Circuit Continuity

Fig 45: Checking Circuit Continuity

Fig 46: Checking Power Supply for A/C Signal Relay

Fig 47: Checking Circuit Continuity

Fig 48: Checking Circuit Continuity

Fig 49: Checking Power Supply for Thermo Control Amp

Fig 50: Checking Circuit Continuity

Fig 51: Checking Circuit Continuity

Fig 52: Checking Output of Auto Amp

Fig 53: Dual-Pressure Switch Continuity

Fig 54: A/C Signal Relay

Fig 55: Connection of Volt Meter

Fig 56: Clutch Disc Wrench

Fig 57: Compressor Clutch (Option 1)

Fig 58: Compressor Clutch (Option 2)

Fig 59: Location of Pin on Clutch Disc Wrench

Fig 60: Clutch Disc Puller

Fig 61: Pulley Installer

Fig 62: Exploded View of V-6 CALSONIC Compressor Clutch

Fig 63: Removing Center Bolt from Compressor Clutch

Fig 64: Using Clutch Puller to Remove Clutch Disc

Fig 65: Removing Snap Ring from Clutch

Fig 66: Removing Compressor Pulley

Fig 67: Removing Field Coil Harness Clip

Fig 68: Removing Snap Ring from Compressor Coil

Fig 69: Inspecting Clutch Disc, Pulley and Coil

Fig 70: Installing Field Coil

Fig 71: Installing Pulley and Snap Ring

Fig 72: Installing Clutch Disc and Shims

Fig 73: Tightening Clutch Disc onto Compressor

Fig 74: Measuring Clutch Disc Clearance

APPLIED MODELS

All models equipped with a retrofitted A/C system

SERVICE INFORMATION

This technical Bulletin details the general service information for all models retrofitted to HFC-134a (R-134a) A/C systems, using an Infiniti approved kit.

This Bulletin also describes the specific details of the G50 model retrofitted to HFC-134a (R-134a) A/C systems.

Refer to the appropriate service Manual, the Retrofit Kit Installation Manual for each model, and ITB92-013 for information not included in the Technical Bulletin.

The Technical Bulletin ITB92-013 (Classification number HA93-002), entitled "A/C SYSTEM CHANGES FOR R-134a REFRIGERANT (All Models)" describes general differences between the R-12 system and the R-124a system.

IMPORTANT POINTS

If the vehicle equipped with retrofit A/C system has a sight glass, do not use the sight glass to check refrigerant level because R-134a and the PAG lubricants do not exhibit "clear sight glass" characteristics, even when properly charged.
When charging R-134a systems, use the ACR4 Recovery/Recycling/ Recharging equipment (J-39500) to insure accurate charging (to .01 lb).
If an R-134a system is suspected to be low on refrigerant charge, first perform a system leak check using the R- 134a leak detector. After repairing any leaks found, charge the system using the ACR4 Recovery/Recycling/Recharging equipment (J-39500).
Use only Infiniti A/C system oil type R for vane rotary compressor, and use only Infiniti A/C System Oil Type S for swash plate compressor and V-6 variable displacement compressor. If another lubricant is used, compressor failure is likely to occur.

TYPICAL REPLACEMENT PARTS FOR RETROFIT A/C SYSTEM

Typical replacement parts for a RETROFIT are shown below. See Fig 1 .

RELIEF VALVE: (Applicable for North America model). The rubber sealing material has been changed.
PRESSURE SWITCH: For cars equipped with low-pressure switch, replace with dual-pressure switch to protect from abnormal pressures.
LIQUID TANK: The dessicant inside the liquid tank has been changed.
OIL: Use PAG oil according to the type of compressor.
CHARGING VALVE ADAPTER: As the charging valve specification has been changed, a newly designed charging valve adapter is required.
EXPANSION VALVE: The refrigerant flow character has been changed.
O-RING: Replace O-rings for pressure switch, expansion valve, and liquid tank as the material has been changed.

PRECAUTIONS AND PREPARATION

Identification for Vehicles Equipped with Retrofit A/C System: See Fig 2 for identification labels and service valve design.

PRECAUTIONS FOR WORKING WITH HFC-134A (R-134A)

CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These refrigerants must never be mixed, even in the smallest amounts. If the refrigerants are mixed, compressor failure is likely to occur.
Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor failure is likely to occur.
The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed:

When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize the entry of moisture from the atmosphere.
When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system.
Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. Without proper sealing, lubricant will become moisture saturated and should not be used.
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from A/C system, using certified service equipment meeting requirements of SAE J2210 (R-134a recycling equipment), or J2209 (R-134a recovery equipment). If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.
Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts. Damage may result.

GENERAL REFRIGERANT PRECAUTIONS

Do not release refrigerant into the air. Use approved recovery/ recycling equipment to capture the refrigerant every time an air conditioning system is discharged.
Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or air conditioning system.
Do not store or heat refrigerant containers above 52°C (125°F).
Do not heat a refrigerant container with an open flame; if container warming is required, place the bottom of the container in a warm pail of water.
Do not intentionally drop, puncture, or incinerate refrigerant containers.
Keep refrigerant away from open flames; poisonous gas will be produced if refrigerant burns.
Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent suffocation.
Do not introduce compressed air to any refrigerant container or refrigerant component.

PRECAUTIONS FOR REFRIGERANT SERVICE

WARNING: Make sure refrigerant is discharged into the recycling equipment and the pressure in the system is less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.

CAUTION: When replacing or cleaning refrigerant cycle components, observe the following.

When the compressor is removed, store it in the same position as it is when mounted on the car. Failure to do so will cause lubricant to enter the low pressure chamber.
When connecting tubes, always use a torque wrench and a back-up wrench. See Fig 3 .
After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture. See Fig 4 .
When installing an air conditioner in the vehicle, connect the pipes as the final stage of the operation. Do not remove the seal caps of pipes and other components until just before required for connection.
Allow components stored in cool areas to warm to working area temperature before removing seal caps. This prevents condensation from forming inside A/C components.
Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
Always replace used O-rings.
When connecting tube, apply lubricant to portions shown in Fig 5 . Be careful not to apply lubricant to threaded portion.
Lubricant Name: Nissan A/C System Oil Type S (For swash plate type compressor and V-6 compressor); Nissan A/C System Oil Type R (For vane rotary type compressor)
Part Number: KLH00-PAGS1 (For swash plate type compressor and V-6 compressor); KLH00-PAGR1 (For vane rotary type compressor)
O-ring must be closely attached to inflated portion of tube. See Fig 5 .
After inserting tube into union until O-ring is no longer visible, tighten nut to specified torque. See Fig 6 .
After connecting line, conduct leak test and make sure that there is no leakage from connections. See Fig 7 . When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten connections of seal seat to the specified torque.

PRECAUTIONS FOR SERVICING COMPRESSOR

Plug all openings to prevent moisture and foreign matter from entering.
When the compressor is removed, store it in the same position as it is when mounted on the car.
When replacing or repairing compressor, follow "MAINTENANCE OF LUBRICANT QUANTITY IN COMPRESSOR" exactly. Refer to the HFC-134A (R-134A) SERVICE PROCEDURES section.
Keep friction surfaces between clutch and pulley clean. If the surface is contaminated with lubricant, wipe it off by using a clean waste cloth moistened with thinner.
After compressor service operation, turn the compressor shaft by hand more than five turns in both directions. This will equally distribute lubricant inside the compressor. After the compressor is installed, let the engine idle and operate the compressor for one hour.
After replacing the compressor magnet clutch, apply voltage to the new one and check for normal operation.

HFC-134A (R-134A) SERVICE TOOLS AND EQUIPMENT

Refrigerant container fittings, service hose fittings, and service equipment fittings (equipment which handles refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid mixed use of the refrigerants/lubricant.

SERVICE TOOLS/EQUIPMENT

Tool Number (Kent-Moore No.) Tool Name	Note
HFC-134a (R-134a) Refrigerant (See Fig 8 )	Container Color: Light blue Container Marking: HFC-134a (R-134a) Fitting Size: Thread Size 14 kg (30 lb) Container 1/2"-16 ACME
KLH00-PAGS1 (-) Nissan A/C System Oil Type S (See Fig 9 )	Type: Poly alkylene glycol oil(PAG), type S Application: HFC-134a (R-134a) Swash Plate (Piston) Compressors (Nissan Only). Lubricity: 40 ml (1.4 US fl.oz., 1.4 Imp fl.oz.)
KLH00-PAGR1 (-) Nissan A/C System Oil Type R (See Fig 9 )	Type: Poly alkylene glycol oil (PAG), type R Application: HFC-134a (R-134a) Vane Rotary Compressors, (Nissan Only). Lubricity: 40 ml (1.4 US fl.oz., 1.4 Imp fl.oz.)
J-39500-NI Recovery/Recycling/ Recharging Equipment (ACR4) (See Fig 10 )	Function: Refrigerant Recovery and Recycling and Recharging
J-39400 Electrical Leak Detector (See Fig 11 )	Power Supply: DC 12V (Cigarette Lighter or Battery Terminals)
J-39183 Manifold Gauge Set (With Hoses and Couplers) (See Fig 12	Identification: The gauge face indicates R-134a. Fitting Size: Thread Size 1/2"-16 ACME Couplers
Service Hoses High Side Hose (J-39501-72) Low Side Hose (J-39502-72) Utility Hose (J-39476-72) (See Fig 13 )	Hose Color: Low Hose: Blue with Black Stripe High Hose: Red with Black Stripe Utility Hose: Yellow w/Black Stripe or Green w/Black Stripe Hose Fitting to Gauge: 1/2"-16 ACME
Service Couplers High Side Coupler (J-39500-20) Low Side Coupler (J-39500-24) (See Fig 14 )	Hose Fitting to Service Hose: M14 x 1.5 Fitting is Optional or Permanently Attached
(J-39650) Refrigerant Weight Scale (See Fig 15 )	For Measuring of Refrigerant Fitting Size: Thread Size 1/2"-16 ACME
(J-39649) Vacuum Pump (Including the Isolator Valve) (See Fig 16 )	Capacity: Air Displacement: 4 CFM Micron Rating: 20 Microns Oil Capacity: 482 g (17 oz) Fitting Size: Thread Size 1/2"-16 ACME

PRECAUTIONS FOR SERVICE EQUIPMENT

RECOVERY/RECYCLING/RECHARGING EQUIPMENT

Be certain to follow the manufacturers instructions for machine operation and machine maintenance. Never introduce any refrigerant other than that specified into the machine.

ELECTRONIC LEAK DETECTOR

Be certain to follow the manufacturers instructions for tester operation and tester maintenance.

VACUUM PUMP

The lubricant contained inside the vacuum pump is not compatible with the specified lubricant for HFC-134a (R-134a) A/C systems. The vent side of the vacuum pump is exposed to atmospheric pressure, so the vacuum pump lubricant may migrate out of the pump into the service hose. This is possible when the pump is switched off after evacuation (vacuuming) and hose is connected to it.

To prevent this migration, use a manual valve placed near the hose-to-pump connection, as described below:

Usually vacuum pumps have a manual isolator valve as part of the pump. See Fig 17 . Close this valve to isolate the service hose from the pump.
For pumps without an isolator, use a hose equipped with a manual shut-off valve near the pump end. See Fig 17 . Close the valve to isolate the hose from the pump.
If the hose has an automatic shut off valve, disconnect the hose from the pump. As long as the hose is connected, the valve is open and lubricating oil may migrate.

Some one-way valves open when vacuum is applied and close under a no vacuum condition. Such valves may restrict the pump's ability to pull a deep vacuum and are not recommended.

MANIFOLD GAUGE SET

Be certain that the gauge face indicates R-134a or 134a. Be sure the gauge set has 1/2"-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant HFC-134a (R-134a) and specified lubricants. See Fig 18 .

SERVICE HOSES

Be certain that the service hoses display the markings described (colored hose with black stripe). See Fig 19 . All hoses must include positive shut off devices (either manual or automatic) near the end of the hoses opposite the manifold gauge. See Fig 20 .

SERVICE COUPLERS

Never attempt to connect HFC1-34a (R-134a) service couplers to a CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will not properly connect to the CFC-12 (R-12) system. However, if an improper connection is attempted, discharging and contamination may occur.

SERVICE COUPLER ROTATION

Shut Off Valve Rotation	A/C Service Valve
Clockwise	Open
Counterclockwise	Close

Refrigerant Weight Scale

Verify that no refrigerant other than HFC-134a (R-134a) and specified lubricants have been used with the scale. If the scale controls refrigerant flow electronically, the hose fitting must be 1/2"-16 ACME. See Fig 21 .

TROUBLE DIAGNOSIS

Fig 75: INSUFFICIENT COOLING DIAGNOSIS - FLOW CHART 1

Fig 76: INSUFFICIENT COOLING DIAGNOSIS - FLOW CHART 2

Fig 77: FLOW CHART A (INSUFFICIENT COOLING DIAGNOSIS - CONT.)

Fig 78: FLOW CHART B (INSUFFICIENT COOLING DIAGNOSIS - CONT.)

PERFORMANCE DATA

General performance characteristics for the CFC-12 (R-12) A/C system and the retrofit A/C system differ. These differences are outlined below.

Recirculating-to-Discharge Air Temperature

The retrofitted A/C system retains the original CFC-12 (R-12) heat exchanger (evaporator and condenser).
Some CFC-12 (R-12) lubrication oil remains in the A/C system.
Because of these two stated reasons the retrofit A/C system has a slightly lower cooling capacity than the CFC-12 (R-12) A/C system. [Maximum discharge air temperature is increased by approximately 2°C (3.6°F).]

Ambient Air Temperature-to-Operating Pressure

The retrofit A/C system has a higher operating pressure than theCFC-12 (R-12) A/C system when the outside air temperature exceeds 15°C (59°F).

High-pressure side (Discharge side): Maximum pressure increase of approximately 294 kPa (3 kg/cm² , 43 psi)
Low-pressure side (Suction side): Same as CFC-12 (R-12) A/C system

Refer to Service Manuals for discharge air temperature and operating pressure values for individual vehicle models. Refer to these Manuals for CFC-12 (R-12) A/C system values.

TROUBLE DIAGNOSIS FOR ABNORMAL PRESSURE

Whenever the high and/or low side pressure is abnormal, diagnose using a manifold gauge. The marker above the gauge scale in the following tables indicates the standard (normal) pressure range. Since the standard (normal) pressure, however, differs from vehicle to vehicle, refer to "Ambient Air Temperature-to-Operating Pressure" under PERFORMANCE DATA.

Fig 79: TABLE A - HIGH & LOW PRESSURE SIDES ARE TOO HIGH

Fig 80: TABLE B - HIGH SIDE TOO HIGH; LOW SIDE TOO LOW

Fig 81: TABLE C - HIGH SIDE TOO LOW; LOW SIDE TOO HIGH

Fig 82: TABLE D - BOTH HIGH & LOW SIDES ARE TOO LOW PART 1

Fig 83: TABLE D - BOTH HIGH & LOW SIDES ARE TOO LOW PART 2

Fig 84: TABLE E - LOW-PRESSURE SIDE SOMETIMES BECOMES NEGATIVE

Fig 85: TABLE F - LOW-PRESSURE SIDE BECOMES NEGATIVE

HFC-134A (R-134A) SERVICE PROCEDURES

Fig 86: SERVICE PROCEDURE FLOW CHART PART 1

Fig 87: SERVICE PROCEDURE FLOW CHART PART 2

DISCHARGING REFRIGERANT

WARNING: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat.

Remove HFC-134a (R-134a) from A/C system using certified service equipment meeting requirements of SAE J2210 HFC-134a (R-134a) recycling equipment or J2209 HFC-134a (R -134a) recovery equipment. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. See Fig 28 .

EVACUATING SYSTEM AND CHARGING REFRIGERANT

See Fig 29 .

MAINTENANCE OF LUBRICANT QUANTITY IN COMPRESSOR

The lubricant used to lubricate the compressor circulates through the system with the refrigerant. Add lubricant to compressor when replacing any component or after repairing a large gas leak. It is important to maintain the specified amount. If lubricant quantity is not maintained properly, the following malfunctions may result:

Lack of lubricant: May lead to a seized compressor
Excessive lubricant: Inadequate cooling (thermal exchange interference)

Lubricant

Swash Plate Compressor And V-6 Compressor
Name: Nissan A/C System Oil Type S

Part number: KLH00-PAGS1
Vane Rotary Compressor
Name: Nissan A/C System Oil Type R

Part number: KLH00-PAGR1

Fig 88: CHECKING AND ADJUSTING PART 1

Fig 89: CHECKING AND ADJUSTING PART 2

Fig 90: FLOW CHART A (MAINTENANCE OF LUBRICANT QTY. CONT.)

TROUBLE DIAGNOSES - G50 SERIES

A/C COMPONENT LAYOUT AND HARNESS LAYOUT

Passenger Compartment

G50 models are equipped with a thermo control amp. to prevent evaporator icing.

In addition, A/C signal relay is adopted to send A/C ON-OFF signal to the ECM (ECCS control module).

The following figures give air conditioning layout of components and wiring diagrams.

Because of the installation of a thermo control amp., Diagnostic Procedure 18 is modified.

SYMPTOM, Magnet clutch does not engage after performing Preliminary Check 6.

Perform Preliminary check 6 before referring to the flow chart.

Fig 91: DIAGNOSTIC PROCEDURE 18 PART 1

Fig 92: DIAGNOSTIC PROCEDURE 18 PART 2

Fig 93: DIAGNOSTIC PROCEDURE 18 PART 3

Fig 94: DIAGNOSTIC PROCEDURE 18 PART 4

Fig 95: DIAGNOSTIC PROCEDURE 18 PART 5

NOTE: = If the result is NG after checking circuit continuity, repair harness or connector.

ELECTRICAL COMPONENTS INSPECTION

For the G5O model the dual-pressure switch operation point is changed. The thermo control amp. and the A/C signal relay are additionally adopted.

Dual-pressure Switch

Check continuity between terminals 55 and 58. See Fig 53 .

DUAL PRESSURE SWITCH CONTINUITY

High-pressure side line pressure kPa (kg/cm² , psi)	Operation	Continuity
Decreasing to 157-196 (1.6-2.0, 23-28) Increasing to 2,648-2,844 (27-29, 384-412)	Turn OFF	Does not exist
Increasing to 157-216 (1.6-2.2, 23-31) Decreasing to 1,863-2,452 (19-25, 270-356)	Turn ON	Exists

A/C Signal Relay Check circuit continuity between terminals by supplying 12 volts to coil side terminal of relay. See Fig 54 .

Thermo Control Amp.

Run engine, and operate A/C system.
Connect the voltmeter from harness side. See Fig 55 .
Check thermo control amp. operation shown in the table below.

THERMO CONTROL AMP OPERATION

Evaporator outlet air temperature °C (°F)	Thermo amp. operation	Tester
Decreasing to 0.5-1.5 (33-35)	Turn OFF	Approx. 12V
Increasing to 2.0-3.0 (36-37)	Turn ON	Approx. 0V

SPECIAL SERVICE TOOLS FOR V-6 COMPRESSOR

On the G50 model, the V-5 compressor is replaced by the V-6 compressor. Use the SPECIAL SERVICE TOOLS FOR V-6 COMPRESSOR table below for the appropriate service tool.

SPECIAL SERVICE TOOLS FOR V-6 COMPRESSOR

Tool Number (Kent-Moore No.) Tool Name	Description
KV99106100 (J-41260) Clutch disc wrench	Removing center bolt (See Fig 56 )
KV99232340 (J-38874) or KV992T0001 Clutch disc puller	Removing clutch disc (See Fig 60 )
KV99106200 (J-41261) Pulley installer	Installing pulley (See Fig 61 )
When replacing the magnet clutch as shown in Fig 57 , use a clutch disc wrench with the pin side on the clutch disc to remove it. See Fig 59 .
When replacing the magnet clutch as shown in Fig 58 , use a clutch Disc wrench with the flat side on the clutch disc to remove it. See Fig 59 .

COMPRESSOR CLUTCH REMOVAL

CLUTCH DISC REMOVAL

Fig 62 illustrates an exploded view of the V-6 CALSONIC Compressor Clutch.

When removing center bolt, hold clutch disc with clutch disc wrench. See Fig 63 .
Remove the clutch disc using the clutch disc puller. See Fig 64 . Insert the holder's three pins into the holes in the clutch disc. Rotate the holder clockwise to hook it onto the plate. Then, tighten the center bolt to remove the clutch disc. After removing the clutch disc, remove the shims from either the drive shaft or the clutch disc.
Remove the snap ring using external snap ring pliers.

PULLEY REMOVAL

Use any commercially available pulley puller. Position the center of it on the end of the drive shaft, and remove the pulley assembly. See Fig 66 .

To prevent the pulley groove from being deformed, the puller claws should be positioned onto the edge of the pulley assembly.

Remove the field coil harness clip using a screwdriver. See Fig 67 .
Remove the snap ring using external snap ring pliers. See Fig 68 .

COMPRESSOR CLUTCH INSPECTION

CLUTCH DISC

If the contact surface shows signs of damage due to excessive heat, replace clutch disc and pulley.

PULLEY

Check the appearance of the pulley assembly. Check the contact surface of the pulley for any sign of excessive grooving due to slippage. If any sign is found, replace both the pulley and clutch disc. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation.

COIL

Check coil for loose connection or racked insulation.

COMPRESSOR CLUTCH INSTALLATION

Install the field coil.
NOTE: Be sure to align the coil's pin with the hole in the compressor's front head. See Fig 70 .
Install the field coil harness clip using a screwdriver.
Install the pulley assembly using the installer and a hand press, and then install the snap ring using snap ring pliers. See Fig 71 .
Install the clutch disc on the drive shaft, together with the original shim(s). See Fig 72 . Press the clutch disc down by hand.
Using the holder to prevent clutch disc rotation, tighten the bolt to 14 N.m (1.4 kg-m, 10 ft-lb) torque. See Fig 73 .
NOTE: After tightening the bolt, check that the pulley rotates smoothly.
Check clearance around the entire periphery of clutch disc. See Fig 74 .

Disc-to-pulley clearance: 0.3 - 0.6 mm (0.012 - 0.024 in)

If the specified clearance is not obtained, replace adjusting spacer and readjust.

When replacing compressor clutch assembly, always conduct the break-in operation. This is done by engaging and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.

GENERAL SPECIFICATIONS

Fig 96: LUBRICANT AND REFRIGERANT TABLE