AC - Compressor Engagement Noise
CATEGORYBody
SECTION
8
PAGE
102
ISSUE
02/95-0549
CODE
854
Subject:
Correcting Complaint of AC Compressor Engagement Noise
Application:
1993-94 9000 Models with R134a refrigerant up to VIN Serial No. Range R1028171
Some customers may complain of unusually loud noise being generated upon engagement of the AC compressor. This is caused by excessive clearance between the compressor clutch drive plate and the belt pulley. Where adjustment of the clearance does not alleviate the complaint, a special rubber-damped driver plate has been developed. (See step 3, p. 3.) This modification was introduced into production from VIN Serial No. R1028171.
The belt pulley should also be changed on vehicles with more than 5,000 miles on the odometer when performing this repair. This should take place to prevent possible noise complaints being generated after this repair has been done if the compressor plate and pulley have established a wear-in pattern or seat.
Cars Affected:
199394 9000 with R134a refrigerant up to
VIN Serial No. R1028171
Parts:
Rubber-damped driver plate 43 83 642
(suitable for all compressor types)
Set of shims for adjusting clearance between
driver plate and belt pulley 46 32 139
Puller 87 91 287
(included in special tools already released)*
A Kit consisting of belt pulley and driver plate can be ordered for cars with more than 5,000 miles:
For 1993 43 83 634
For 1994 43 83 626
Special Tool Ordering:
*Puller, P/N 87 91 287, is available for purchase from Kent-Moore by calling the Kent-Moore order desk at 1-800-345-2233. During 1993 this item was deleted from the list of essential tools. Many dealers still have one of these on hand so check your tool supplies before ordering.
Action:
^ First check and adjust the clearance between the belt pulley and compressor clutch driver plate as described on the next page.
^ Fit a rubber-damped driver plate instead of the existing driver plate as described on page 3 if adjustment does not rectify the complaint.
The belt pulley should also be changed on cars with more than 5,000 miles.
Adjusting the clearance:
1. Check the clearance between the belt pulley and driver plate by measuring it at three different points and calculating the average. The average clearance should be 0.3-0.6 mm. See Figure 1.A.
Proceed to "Fining the rubber clutch" if the clearance is ok. Continue as described below if the clearance is not ok.
2. Remove the compressor retaining bolts and rest the compressor on the radiator member, protecting the paint.
3. Remove the driver plate using an Allen key. Hold the driver plate with a pair of slip-joint pliers to prevent it from moving. See Figure 1.B.
4. Adjust the clearance between the belt pulley and driver plate by changing the shims on the compressor shaft. See Figure 1.C.
5. Fit the felt sleeve in place on the driver plate. See Figure 1.D.
6. Refit the driver plate.
Tightening torque: 15 Nm (11 ft.lbs.).
7. Check that the average clearance between the belt pulley and driver plate is between 0.3 and 0.6mm as described in point 1.
8. Fit the compressor in place and tighten the three retaining bolts. Note that the bracket for the electrical connection is held in place by the top left-hand bolt.
9. Check whether the noise made when the compressor engages in has been reduced to an acceptable level.
10. If the noise is still present, proceed to "Fitting the rubber clutch."
Fitting the rubber clutch
Cars with less than 5,000 miles:
1. Remove the compressor retaining bolts and rest the compressor on the radiator member. Protect the paint-work.
2. Remove the driver plate.
3. Fit the rubber-damped driver plate in position.
4. Check the clearance between the driver plate and belt pulley and adjust if necessary as described.
5. Fit the compressor in place and tighten the three retaining bolts. Note that the bracket for the electrical connection is held in place by the top left-hand bolts.
Cars with more than 5,000 miles:
1. Remove the compressor retaining bolts and rest the compressor on the radiator member. Protect the paintwork.
2. Remove the driver plate.
3. Remove the circle from the belt pulley and pull the pulley off the shaft, using puller P/N 87 91 297. See Figure 2.
4. Fit a new belt pulley. Refit the circlip.
5. Fit the rubber-clamped driver plate in position.
6. Check the clearance between the driver plate and belt pulley and adjust if necessary as described under Adjusting the clearance.
7. Fit the compressor in place and tighten the three retaining bolts. Note that the bracket for the electrical connection is held in place by the top left-hand bolt.
Warranty Information:
To resolve a customer complaint for a vehicle in warranty, submit a claim using the following information:
Failure code: 87011-40-0-01-05.
Straight time allowance to adjust clearance is 0.4 hr. Straight time allowance to R & R clutch is 0.3 hr.