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WITH DIESEL ENGINE
1. Using recycling and recovery equipment (for HFC-134a), discharge the refrigerant.
2. Remove the engine under cover.
3. Remove the compressor-alternator belt.
Refer to EM-12, "
Removal and Installation" or EM-13, "Removal and Installation of Drive Belt Auto-Ten-
sioner" for QR engine,EM-119, "Removal and Installation" for YD engine.
4. Remove the mounting nuts (bolts) from the high-pressure flexi-
ble hose and low-pressure flexible hose.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
5. Disconnect the compressor connector.
RHA667H
RJIA0073E
RJIA0579E
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6. Remove the mounting bolts from compressor.
7. Remove the compressor from the lower side of the vehicle.
INSTALLATION
CAUTION:
●Replace the O-ring of the low-pressure flexible hose and
high-pressure flexible hose with a new one, then apply
compressor oil to it when installing it.
●When pouring refrigerant, check for leaks.
RJIA0021E
RJIA0580E
RJIA0023E
RJIA0581E
Bolts mounting the compressor (With gasoline engine)
Tightening torque : 28.4 - 33.3 N-m (2.9 - 3.4 kg-m, 21 - 24 ft- lb)
Bolts mounting the compressor (With diesel engine)
Tightening torque : 60 - 69 N-m (6.1 - 7.1 kg-m, 45 - 51 ft- lb)
Nut (bolt) mounting the high-pressure flexible hose
Tightening torque : 8 - 18 N-m (0.8 - 1.9 kg-m, 70 - 164 in-lb)
Nut (bolt) mounting the low-pressure flexible hose
Tightening torque : 8 - 18 N-m (0.8 - 1.9 kg-m, 70 - 164 in-lb)
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Removal and Installation for Compressor ClutchEJS000VA
REMOVAL
Overhaul (With Gasoline Engine: CWV-615M Compressor)
1. When removing center bolt, hold clutch disc with wrench.
2. Remove the clutch disc using the clutch disc puller.
3. Remove the snap ring using external snap ring pliers.
RHA136EB
RHA399F
RHA124F
RHA138E
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4. Position the center pulley puller on the end of the drive shaft,
and remove the pulley assembly using any commercially avail-
able pulley puller.
To prevent the pulley groove from being deformed, the puller
claws should be positioned into the edge of the pulley assembly.
5. Remove the field coil harness clip using a pair of pliers.
6. Remove the snap ring using external snap ring pliers.
Overhaul (With Diesel Engine: DKV-11G Compressor)
1. Remove the two screws holding the connector bracket, thermal
protector to the compressor.
RHA139E
RHA125F
RHA145E
RHA669H
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2. When removing center bolt, hold clutch disc with clutch disc
wrench.
3. Remove the drive plate using the clutch disc puller.
4. Insert holder's three pins into the drive plate. Rotate the holder
clockwise to hook it onto the plate.
5. Tighten the center bolt to remove the drive plate.
6. While tightening the center bolt, insert a screwdriver between
two of the pins (as shown in the figure) to prevent rotation.
7. After removing the drive plate, remove the shims from either the
drive shaft or the drive plate.
8. Remove the snap ring using external snap ring pliers.
9. Remove the pulley assembly with the puller using a commer-
cially available pulley puller. (Position the center of the puller on
the end of the drive shaft)
For pressed pulleys:
To prevent deformation of the pulley groove, the puller claws
should be hooked under (not into) the pulley groove.
For machine lathed pulleys:
Align the pulley puller groove with the pulley groove, and then
remove the pulley assembly.
10. Remove the field coil harness clip using a screwdriver.
11. Then remove the three field coil fixing screws and remove the
field coil.
SHA097EA
ZHA093H
RHA072C
SHA099EA
RHA074C
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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. If the contact surface
of pulley sows signs of excessive grooving, replace clutch disc and
pulley. The contact surfaces of the pulley assembly should be
cleaned with a suitable solvent before reinstallation.
Coil
Check coil for loose connection or cracked insulation.
INSTALLATION
With Gasoline Engine (CWV-615M Compressor)
1. Install the field coil.
Be sure to align the coil's pin with the hole in the compressor's
front head.
2. Install the field coil harness clip using a screwdriver.
3. Install the pulley assembly using the installer and a hand press,
and then install the snap ring using snap ring pliers.
RJIA0582E
RJIA0583E
RHA142E
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4. Install the clutch disc on the drive shaft, together with the original
shim(s). Press the clutch disc down by hand.
5. Using the holder to prevent clutch disc rotation.
After tightening the bolt, check that the pulley rotates smoothly.
6. Check clearance around the entire periphery of clutch disc.
If the specified clearance is not obtained, replace adjusting
spacer and readjust.
With Diesel Engine (DKV-11G Compressor)
1. Install the field coil.
Be sure to align the coil's pin with the hole in the compressor's
front head.
2. Install the field coil harness clip using a screwdriver.
RHA127F
Tightening torque : 14 N-m (1.4 kg-m, 10 ft-lb)
RHA086E
Disc to pulley clear-
ance: 0.3 - 0.6 mm (0.012 - 0.024 in)
RHA087E
RHA076C
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3. Install the pulley assembly using the installer and a hand press,
and then install the snap ring using snap ring pliers.
4. Install the drive plate on the drive shaft, together with the original
shim(s). Press the clutch disc down by hand.
5. Using the holder to prevent clutch disc rotation.
After tightening the bolt, check that the pulley rotates smoothly.
6. Check clearance around the entire periphery of clutch disc.
If the specified clearance is not obtained, replace adjusting
spacer and readjust.
ZHA094H
RHA078C
Tightening torque : 12 - 15 N-m (1.2 - 1.5 kg-m, 9
- 10 ft-lb)
SHA101EA
Disc to pulley clear-
ance: 0.2 - 0.5 mm (0.008 - 0.020 in)
RHA080CA