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Clutch Plate and Hub Assembly Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2005 Suzuki Reno and 2005 Suzuki Forenza. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the clutch hub key into the hub keyway. Allow the key to project approximately 3.2 mm (1/8 inch) out of the keyway. The hub key is curved slightly to provide an interference fit in the hub key groove.
  2. Be sure the frictional surface of the clutch plate and the pulley rotor are clean before installing the clutch drive plate and the hub assembly.
    CAUTION: Do not drive or pound on the clutch hub or the shaft. Internal damage to the compressor may result.
    Fig 1: Installing Clutch Hub Key Into Hub Keyway
    G04104150Courtesy of SUZUKI OF AMERICA CORP.
  3. Align the clutch hub key with the shaft keyway. Place the clutch drive plate and the hub assembly onto the compressor shaft.
  4. Remove the hub and drive plate remover/installer J-33013-B center bolt and reverse the body direction on the center bolt. The body of the hub and drive plate remover/installer J-33013-B should be backed off sufficiently to allow the center bolt to be threaded onto the end of the compressor shaft.
    CAUTION: If the center bolt is threaded fully onto the end of the compressor shaft, or if the body of the hub and drive plate remover/installer J-33013-B is held and the center bolt is rotated, the key will wedge and could break the clutch drive plate and the hub assembly.
  5. Install the hub and drive plate remover/installer J-33013-B and the bearing onto the clutch drive plate. Thread the center bolt onto the compressor shaft.
  6. Hold the center bolt with a wrench. Tighten the hex portion of the hub and drive plate remover/installer J-33013-B body to press the hub onto the shaft. Tighten the body several turns.
  7. Remove the hub and drive plate remover/installer J-33013-B and check to see that the clutch hub key is still in place in the keyway before installing the clutch drive plate and the hub assembly to its final position. The air gap between frictional surfaces of the clutch drive plate and the clutch pulley rotor should be 0.38 to 0.64 mm (0.015 to 0.025 inch.).
    Fig 2: Removing Hub And Drive Plate
    G04104151Courtesy of SUZUKI OF AMERICA CORP.
  8. Remove the hub and drive plate remover/installer J-33013-B. Check for proper positioning of the clutch hub key. It should be even or slightly above the clutch hub.
  9. Install the shaft nut. Hold the clutch drive plate and the hub assembly with the clutch hub holding tool J-33027. Use the shaft nut socket J-33022 and tighten the nut against the compressor shaft shoulder.

    Tighten 

    Tighten the clutch plate and hub assembly retaining nut to 17 N.m (13lb-ft).

  10. Spin the pulley rotor by hand to verify that the pulley is not rubbing the clutch drive plate.
    Fig 3: Holding Clutch Drive Plate And Hub Assembly Installing Shaft Nut
    G04104152Courtesy of SUZUKI OF AMERICA CORP.
  11. Remove the compressor from the bench vise and remove the J-34992 compressor holding fixture from the compressor.
  12. Install the compressor. Refer to "COMPRESSOR REMOVAL AND INSTALLATION :".
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