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Thread: Winter Chassis Re-fresh

  1. #131

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    Hi Kaz,

    As soon as all the parts arrive, I'll post an update to answer your questions.

    I'm with you though on the new pulley/clutch from Rock Auto, I think it will be '91-'96 spec. Hopefully with the '97 mounting bracket & whatever the pulley does turn out to be, I have all the components to mount the new compressor correctly.

    The connector on 471-1194 does indeed have the wrong electrical connector & the smaller diameter pulley, which I will measure when next in the garage.
    Wix

  2. #132

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    Parts have arrived, so here's some photos to answer some of the questions on an earlier post.

    New pulley & clutch from Rock Auto, large diameter
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    pulley from new compressor 471-1194, small diameter
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    Rock Auto pulley against new Compressor 471-1194
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    and against the original R12 compressor from my car
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    Rock Auto Actuator against original R12 are the same
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    and '97 mounting bracket.
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    and a few more parts
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    I think the Rock Auto pulley/clutch assy is the later '97 offset, as it doesn't have the same offset as the original off my car. Confirmation when I've actually assembled them to the new compressor.
    Wix

  3. #133
    Join Date
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    Hi, Wix.
    Thank you for taking your time for all these feedback.
    Much appreciated.




    Interesting to see where the pulley sits once the snap ring installed.

    Kaz

  4. #134

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    No probs Kaz, glad to help confirm all the fitment issues with a compressor change to R134.

    Original R12 compressor hose attachment plate removed, internals look clean, which is a good sign.
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    This compares the original '91-'96 compressor pulley alignment with the 471-1194 with the Rock Auto pulley assy. As can be seen, the Rock Auto assy is most definitely the later '97 offset, the belt run being closer to the compressor body.
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    New tensioner pulley & adjustment screw attached, the bracket cleaned up quite well.
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    New compressor & Rock Auto pulley attached to the original '91-'96 compressor mounting bracket. Photo doesn't really, due to fish effects but there is a definite mis-alignment.
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    Old '91-'96 bracket off the engine & the new '97 bracket.
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    Completed assy now mounted to the '97 bracket.
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    with the belt on, which shows perfect alignment.
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    Changed a few more air-con pipe seals, one of the old & new from the compressor hoses. Needless to say but they weren't in the best shape, so maybe the seals were the cause of the gas leakage.
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    So final spec, for future reference.

    Rock Auto pulley/clutch/actuator assy - Four Seasons (no Denso parts available at time of ordering) - 47598 ('97 MY Pulley offset)
    Denso R134 compressor 471-1194
    '97 MY compressor mounting bracket 38930-PR7-A01
    Wix

  5. #135

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    More fun in the garage today,

    dry fit of new driveshaft & intermediate shaft
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    New intermediate shaft has a larger shaft diameter, I guess this was an specification upgrade during the cars life.
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    and more air-con seal changes
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    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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    Wix

  6. #136

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    Hopefully this will be the final chapter in this winters overhaul. Fitted the last few bits back to the car, filled the gearbox with MTF3 & torqued everything up. Then came the moment to start the car & test to see that the clutch operated correctly, with it still on the ramp. BUT, I couldn't engage any gears properly & couldn't get into reverse at all, there was definitely no proper dis-engagement of the clutch........As you might guess, the air became a tad blue, at the possibility of having to remove the gearbox & clutch again.

    After an email to Kaz & doing a few searches on the forums, I had a few ideas. Kaz suggested re-doing the clutch initialisation procedure & checking the pedal travel adjustment. Apparently the mid plate could get knocked out of place, if you struggle to get the gearbox back onto the engine, which did happen to me, working alone. I'd definitely recommend getting an assistant for anyone else who might attempt to do a DIY clutch change.

    I re-set the initialisation and clutch pedal travel as per Kaz's video & re tested to see if the gears selected correctly & success, every gear could be engaged easily including reverse. I have yet to test drive the car, as I need to borrow a torque wrench to tighten the driveshaft axle nuts up, my largest torque wrench maxes out at 210n/m & the nut is 335n/m but fingers crossed, there'll be no more gear selection issues when I do go for a drive.

    I also replaced the two air-con pipe seals at the front bulkhead. Not the easiest of tasks.....

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    but the two seals were in good shape, compared to some of the other seals I've replaced from the under floor connections but new ones now in the cleaned up joints.
    Wix

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