Removal and Installation - Turbo Engine

REMOVAL

NOTE: The A/C compressor clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley and bearing assembly, or coil replacement.

1. Disconnect and isolate negative battery cable.
2. Remove the accessory drive belt.
3. Raise and support the vehicle.
4. Disconnect the wire harness connector from the clutch field coil connector on the A/C compressor.
5. Remove the bolts that secure the A/C compressor to the mounting bracket.
6. Remove the A/C compressor from the mounting bracket and support the compressor while servicing the clutch.

A/C Clutch - Typical:

7. Insert the pins of the spanner wrench (Special Tool 6462 in Kit 6460) into the holes of the clutch plate. Hold the clutch plate stationary with the spanner wrench and remove the clutch nut.
8. Remove the clutch plate with puller (Special Tool 6461 in Kit 6460).
9. Remove the clutch shims from the compressor shaft.

Front Housing Hub External Snap Ring:

10. Remove the snap ring that secures the pulley and bearing assembly to the compressor with snap ring pliers.

Shaft Protector And Puller Jaws:

11. Install the lip of the puller jaws (Special Tool 6141-1 in Kit 6125) into the front housing hub external snap ring groove and install the shaft protector (Special Tool 6141-2 in Kit 6125).

Puller And Jaws:

12. Install the bolts for puller (Special Tool 6461 in Kit 6460) through the puller flange and into the puller jaws. Tighten the bolts securely.
13. Turn the puller center-bolt clockwise until the pulley and bearing assembly is completely removed from the front housing hub.

Clutch Coil Wire Harness:

14. Remove the screw that secures the clutch coil wire harness retainer clip to the compressor front housing.

A/C Clutch Field Coil Snap Ring:

15. Remove the snap ring that secures the A/C clutch field coil to the compressor front housing..
16. Remove the clutch field coil from the compressor.

INSTALLATION
1. Position the A/C clutch field coil onto the A/C compressor front housing.
2. Install the snap ring that secures the clutch field coil to the compressor front housing with snap ring pliers.

NOTE: Care must be taken not to pinch the wire harness with the retaining clip when tightening the retaining screw.

3. Install the screw that secures the clutch coil wire harness retainer clip to the compressor front housing. Tighten the screw securely.
4. Align the pulley and bearing assembly squarely onto the compressor front housing hub.

A/C Clutch Pulley Installer:

5. Install the pulley and bearing assembly onto the compressor front housing hub with installer (Special Tool 6871. Thread the installer onto the compressor shaft, then turn the installer nut until the pulley and bearing assembly is seated against the compressor front housing.

CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in a clutch failure and severe damage to the front housing of the compressor.

NOTE: Install the snap ring with the beveled side of the snap ring facing outward.

6. Install the snap ring that secures the pulley and bearing assembly to the compressor. Press the snap ring to make sure it is properly seated in the groove.
7. Verify that there is adequate clearance between the clutch field coil wire and the clutch pulley.

NOTE: When installing an original, or a new clutch assembly, try the original shims first. When installing a clutch onto a compressor that previously did not have a clutch, use 1.0, 0.50, and 0.13 millimeter (0.040, 0.020, and 0.005 inch) shims from the clutch hardware package that is provided with the new clutch.

8. Install the clutch shims onto the compressor shaft.

NOTE: A distinct change of sound during the clutch plate tapping process indicates that the clutch plate has bottomed out against the compressor clutch shims.

A/C Clutch Plate And Driver:

9. Install the clutch plate using driver (Special Tool 6463 in Kit 6460). Tap the clutch plate over the compressor shaft until it has bottomed against the clutch shims.
10. Install the clutch nut onto the compressor shaft. Tighten the nut to 17.5 N.m (155 in. lbs.).

A/C Clutch Air Gap:

11. Check the clutch air gap with a feeler gauge. If the air gap does not meet the specification, add or subtract shims as required. The air gap specification is 0.33 to 0.63 millimeter (0.013 to 0.025 inch).
12. Position the A/C compressor onto the mounting bracket.
13. Install the bolts that secure the A/C compressor to the mounting bracket. Tighten the bolts to 28 N.m (20 ft. lbs.).
14. Connect the wire harness to the compressor clutch field coil connector.
15. Lower the vehicle.
16. Install the accessory drive belt.
17. Reconnect the negative battery cable.
18. Perform the Clutch Break-in Procedure.