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Clutch Rotor and Bearing Assembly

WARNING: This page is about a different car, the 2006 Suzuki Verona. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Do not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face could be damaged.
  1. Invert the pulley rotor and place it on a support block to fully support the rotor hub during bearing installation.
  2. Align the new bearing squarely in the pulley bore. Use the bearing installer J-9481 and the driver handle J-8092, drive the bearing fully into the pulley bore.
    Fig 1: Driving Bearing Fully Into Pulley Bore Using Bearing Installer J-9481 & Driver Handle J-8092
    G04717835Courtesy of SUZUKI OF AMERICA CORP.
  3. Place the bearing staking guide J-33019-1 and the bearing staking pin J-33019-2 in the rotor hub core. Shift the rotor and bearing assembly on the block to give full support to the hub under the staking pin. A heavy-duty rubber band may be used to hold the staking tool pin in the guide. The pin should be properly positioned in the guide after each impact on the pin.
    Fig 2: Installing Bearing Staking Guide & Pin In Rotor Hub Core
    G04720038Courtesy of SUZUKI OF AMERICA CORP.
  4. Strike the pin with a hammer until a metal stake, similar to the original, is formed down to, but not touching, the bearing. The metal stake should not contact the outer race of the bearing to avoid the possibility of distorting the outer race. Stake in 3 places 120° apart.
    WARNING: When striking the pin with a hammer, take care to avoid personal injury.
    Fig 3: Identifying Pulley Rotor
    G04717837Courtesy of SUZUKI OF AMERICA CORP.
  5. With the compressor mounted to the holding fixture J-34992, position the rotor and bearing assembly on the compressor housing.
  6. Position the pulley rotor and bearing installer J-33017 and the puller pilot J-33023-A directly over the inner race of the bearing.
  7. Position the puller crossbar J-8433-1 center forcing bolt on the puller pilot J-33023-A and assemble the 2 through-bolts and the washers through the slots on the puller crossbar J-8433-1. Thread the through-bolts into the holding fixture J-34992. The thread of the through-bolts should engage the full thickness of the fixture.
  8. Tighten the center forcing screw J-8433-3 in the puller crossbar J-8433-1 to force the pulley rotor and bearing assembly onto the compressor housing.
    Fig 4: Assembling Rotor & Bearing Assembly Using Special Tools
    G04717838Courtesy of SUZUKI OF AMERICA CORP.
  9. Install the rotor and bearing assembly retainer ring using the snap ring pliers J-6083.
  10. Reinstall the clutch drive plate and hub assembly. Refer to Clutch Plate and Hub Assembly Reassembly .
  11. Install the compressor. Refer to Compressor Installation .
  12. Connect the negative battery cable.
  13. Evacuate and recharge the A/C system. Refer to Discharging, Adding Oil, Evacuating and Charging Procedures for A/C System .
    Fig 5: Installing Rotor And Bearing Assembly Retainer Ring Using Snap Ring Pliers J-6083
    G04717839Courtesy of SUZUKI OF AMERICA CORP.
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