Compressor Clutch: Service and Repair
REMOVALNOTE: 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 Bolt:
7. Install the compressor clutch holding fixture (Special Tool 9351 in Kit 9349) onto the clutch plate. Hold the clutch plate stationary with the holding fixture and remove the clutch bolt.
NOTE: The clutch plate can be removed from the compressor shaft by hand or, if required, pressed off with an 8 x 1.25 mm bolt.
8. Remove the clutch plate from the compressor shaft. If required, install a 8 x 1.25 mm bolt into the center of the clutch plate and turn the bolt clockwise until the clutch plate is completely removed from the compressor shaft.
9. Remove the clutch shims from the compressor shaft.
Front Housing Hub Snap Ring:
10. Remove the snap ring that secures the pulley and bearing assembly to the compressor with snap ring pliers.
NOTE: The pulley and bearing assembly can be removed from the compressor by hand or, if required, with a two jaw puller.
A/C Clutch Pulley And Bearing:
11. Remove the pulley and bearing assembly from the compressor. If required, install a two jaw puller and turn the puller center-bolt clockwise until the pulley and bearing assembly is completely removed from the front housing hub.
A/C Clutch Field Coil:
12. Remove the screw that secures the clutch coil wire harness connector bracket to the compressor.
13. Remove the clutch field coil from the compressor with the compressor field coil remover (Special Tool 9354 in Kit 9349) and a two jaw puller.
INSTALLATION
1. Align the A/C clutch field coil squarely onto the A/C compressor housing front hub.
NOTE: Position the A/C clutch coil so that the coil positioning tab and the wire harness connector is oriented in the correct direction.
Clutch Field Coil:
2. Install the clutch field coil onto the compressor with the compressor field coil installer (Special Tool 9352 in Kit 9349), compressor field coil installer spacer (Special Tool 9353 in Kit 9349) and a two jaw puller.
3. Install the screw that secures the clutch coil wire harness connector to the compressor housing. Tighten the screw to 2 N.m (17 in. lbs.).
4. Align the pulley and bearing assembly squarely onto the compressor front housing hub.
NOTE: A distinct change of sound during the clutch pulley tapping process indicates that the pulley and bearing assembly has bottomed out against the compressor housing.
Clutch Pulley Installer:
5. Install the pulley and bearing assembly onto the compressor housing front hub with the clutch pulley installer (Special Tool 9355 in Kit 9349). Tap the installer with a hammer until the pulley and bearing assembly has bottomed against the compressor 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.
A/C Clutch Bolt:
9. Install the clutch plate and bolt with the compressor clutch holding fixture (Special Tool 9351 in Kit 9349). Hold the clutch plate stationary with the holding fixture and install the clutch bolt. Tighten the bolt to 13 N.m (115 in. lbs.).
Clutch Air Gap:
10. 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 0.35 to 0.75 millimeter (0.014 to 0.030 inch).
11. Position the A/C compressor onto the mounting bracket.
12. Install the bolts that secure the A/C compressor to the mounting bracket. Tighten the bolts to 28 N.m (20 ft. lbs.).
13. Connect the wire harness to the compressor clutch field coil connector.
14. Lower the vehicle.
15. Install the accessory drive belt.
16. Reconnect the negative battery cable.
17. Perform the Clutch Break-in Procedure.