Honda Civic Service Manual: A/C Compressor Clutch Overhaul (K24Z7)

1.

Remove the center nut while holding the armature plate (A) with the A/C clutch holder (B).

NOTE: Do not hammer or pry on the rotor pulley to remove it. Using a hammer damages the A/C compressor. If the rotor pulley is difficult to remove, use a commercially available pulley removing tool. Make sure the jaws of the pulling tool engage the back face of the rotor pulley, not the rotor pulley grooves.

2.

Remove the armature plate (A) and the shim(s) (B), taking care not to lose the shim(s).

NOTE:

1.

Remove the snap ring (A) with the snap ring pliers.

2.

Remove the rotor pulley (B).

NOTE: Be careful not to damage the rotor pulley or the A/C compressor.

1.

Remove the holders (A).

2.

Disconnect the connector (B).

3.

Remove the snap ring (C) with the snap ring pliers.

4.

Remove the field coil (D). Be careful not to damage the field coil and A/C compressor.

NOTE: Inspect the friction surfaces and the compressor shaft hub for excess oil. If excess oil is present, and it is not from the engine or power steering system, then the compressor shaft seal is leaking. Replace the A/C compressor.

When replacing the field coil, check that the new coil has the correct resistance.

Install the field coil with the wire side facing down, and align the boss on the field coil with the hole in the A/C compressor.

Clean the rotor pulley and the armature plate with contact cleaner or other non-petroleum solvent.

Install new snap rings, note the installation direction, and make sure they are fully seated in the grooves.

Make sure that the rotor pulley turns smoothly after it's reassembled.

Route and clamp the wires properly to prevent damage by the rotor pulley.

After reinstallation, cycle the A/C clutch approximately 20 times by running the engine at 1,500-2,000 rpm and setting the A/C system to MAX A/C mode. This procedure seats the clutch sliding surfaces, and increases clutch torque capacity.

1.

Install the field coil (A).

NOTE: Be careful not to damage the field coil and A/C compressor.

2.

Install the snap ring (B) with the snap ring pliers.

3.

Connect the connector (C).

4.

Install the holder (D).

1.

Install the rotor pulley (A).

NOTE: Be careful not to damage the rotor pulley or the A/C compressor.

2.

Install the snap ring (B) with the snap ring pliers.

1.

Install the armature plate (A) and the shim(s) (B), taking care not to lose the shim(s). If the clutch needs adjustment, increase or decrease the number and thickness of shims as necessary, then reinstall the armature plate, and recheck its clearance.

NOTE: The shims are available in four thicknesses: 0.1 mm, 0.2 mm, 0.4 mm, and 0.5 mm.

2.

Install the center nut while holding the armature plate (A) with the A/C clutch holder (B).

1.

Check the armature plate for discoloration, peeling, or other damage. If there is damage, replace the clutch set.

2.

Inspect the friction surfaces and the compressor shaft hub for excess oil. If excess oil is present, and it is not from the engine or power steering system, then the compressor shaft seal is leaking. Replace the A/C compressor.

3.

Check the rotor pulley bearing play and drag by rotating the rotor pulley by hand. Also check for grease leakage from the bearing. Replace the clutch set with a new one if it is noisy, has excessive play/drag, or has bearing grease contamination on the clutch faces.

NOTE: The rotor pulley and the armature plate were mated at the factory by a burnishing operation. Always replace the rotor pulley and the plate as a set. Replacing only one part of the clutch set will cause clutch slippage.

4.

Measure the clearance between the rotor pulley (A) and the armature plate (B) all the way around. If the clearance is not within specified limits, remove the armature plate and add or remove shims as needed to increase or decrease clearance.

Clearance: 0.35－0.65 mm (0.014－0.025 in)

NOTE: The shims are available in four thicknesses: 0.1 mm, 0.2 mm, 0.4 mm, and 0.5 mm.

5.

USA and Canada models: Check for continuity between the A/C compressor clutch connector terminals No. 2 and No. 3. If there is no continuity, replace the thermal protector.

NOTE: The thermal protector will have no continuity above about 252 to 262 °F (122 to 128 °C). When the temperature drops below about 241 to 219 °F (116 to 104 °C), the thermal protector will have continuity.

6.

Mexico models: Disconnect the connector (A).

7.

Mexico models: Check the thermal protector for continuity. If there is no continuity, replace the thermal protector.

NOTE: The thermal protector will have no continuity above 252 to 262 °F (122 to 128 °C). When the temperature drops below 241 to 219 °F (116 to 104 °C), the thermal protector will have continuity.

8.

USA and Canada models: Disconnect the connector (A).

9.

Measure the resistance of the field coil. If resistance is not within specifications, replace the field coil.

Field Coil Resistance: 3.15－3.45 Ω at 68 °F (20 °C)