A/C Compressor Clutch Replacement

REMOVAL
1. Remove the compressor from the mount.

Compressor Shaft Nut Removal/Installation:

2. Install two (6 mm) bolts into the threaded holes in the armature plate. Hold bolts with two wrenches to prevent shaft from turning. Remove compressor shaft nut.

Clutch Plate/Pulley/Field Coil:

3. Lightly tap clutch plate with a plastic hammer and remove plate and shim(s).

CAUTION: Do not use screwdrivers between the armature plate assembly and rotor-pulley to remove the armature plate. This may damage the armature plate assembly.

4. Remove pulley retaining snap ring with snap ring pliers. Remove pulley assembly from compressor. Use a plastic hammer, if necessary.
5. Loosen the lead wire retaining clamps and remove lead wire from the compressor front end cover. Disconnect the lead wire from the thermal limiter switch.
6. Remove snap ring which secures field coil-core assembly to the front cover. Note the alignment of field coil-core assembly when removing.

WARNING: TAKE CARE THAT THE SNAP RING DOES NOT FLY OUT FROM THE GROOVE.

INSPECTION
Examine frictional faces of the rotor-pulley and armature plate for wear. The pulley and plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for excess oil. If excess oil is present, the shaft seal is leaking and the compressor must be replaced.

Check pulley hub bearing for roughness or excessive grease leakage. Check for bearing grease contamination on armature plate faces.

CAUTION: The pulley and clutch plate were mated at the factory by a burnishing operation. No attempt should be made to separately replace either part. This will result in clutch slippage due to insufficient contact area.

INSTALLATION
1. Position the back of the field coil on the compressor front cover. Be sure the locating nipple on the back of the coil lines up with the locating indentation on the front cover. This ensures correct position of the coil and lead wire.
2. Fasten lead wire to the compressor front cover with the retaining clip. Connect the lead wire to the thermal limiter switch.
3. Install field coil retaining snap ring (bevel side outward) with snap ring pliers. Insure snap ring is properly seated into groove.

CAUTION: If snap rings on field coil or pulley assembly are not fully seated, they will vibrate out. A clutch failure and possible severe damage to the compressor could result.

4. Position pulley assembly onto compressor.

CAUTION: Do not mar the pulley frictional surface.

5. Install pulley assembly retaining snap ring (bevel side outward) with snap ring pliers. Insure snap ring is properly seated into groove.
6. Place a trial stack of shims, 2.54 mm (0.10 in.) thick, on the compressor shaft.

Aligning Clutch Plate Splines:

7. Install clutch plate on compressor shaft. Note the machined mating splines.

Measuring Air Gap:

8. With the front clutch plate assembly tight against the shims, measure the air gap between clutch plate and pulley face with feeler gauges. The air gap should be between 0.35 and 0.65 mm (0.013 and 0.025 inch). If proper air gap is not obtained, add or subtract shims until desired air gap is obtained.
9. Install compressor shaft nut. Tighten nut to 17.6 Nm (13 ft. lbs.) torque.
10. Shims may compress after tightening shaft bolt. Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check.
11. Install the compressor onto the mount.