Engine Size: 2.3
Country of Origin: Japan
Replaced the OEM Denso compressor with same (new) about 14 months ago. Compressor was ok, just had a wobbly, noisy clutch bearing so replaced all at 115,00 miles. Did not flush system. New TXV, Receiver. Very carefully measured oil for all new components per factory manual. Vacuum held, charged system by weight (17.5 oz) Ran cold and normal for 1.2 years. One Monday morning about three weeks ago (after the car sat all weekend), I thought I heard an 'unusual' noise when I hit the "AC button". The rest of the week, just cold air. Happened again a couple weeks later, 'clunky' sound from compressor when first switched on after sitting the weekend, but then normal the rest of the week. This past Tuesday after the holiday, the startup clunk was major, and the clutch stuck engaged (even with the lead disconnected). Today, while checking things in a 'static condition', the clutch released with a screwdriver tap. I removed the compressor assembly and, after removing the clutch, the faces look normal, and the compressor turns freely (has the same feel as the old Denso). Can't find a sign of debris anywhere. If this thing has started slugging after sitting for a few days, why would it start doing it 1.2 years after the install? Can it be weather related? (hot and extremely humid) What am I overlooking or what else to check? Before today's disassembly, the last pressures I saw at 78 deg. ambient and high humidity were 130 high and 18 low. That's with the clutch wire disconnected (clutch was stuck) and condenser fans on.
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