Compressor Clutch: Service and Repair
REMOVAL
NOTE: The compressor clutch assembly can be serviced with the refrigerant system fully charged and with the A/C compressor installed on the engine.
1. Disconnect and isolate the negative battery cable.
2. On 5.7L and 6.1L engine equipped vehicles, remove the air intake hose and the air cleaner housing.
3. Remove the radiator fan and shroud assembly.
4. Remove the accessory drive belt.
5. Disconnect the engine wire harness from the compressor clutch field coil connector (1) located on the top of the A/C compressor (5).
NOTE: Some models (depending on engine application) may require the A/C compressor to be removed from its installed location to gain access to the compressor shaft bolt and/or pulley and field coil snap rings. However, the refrigerant system can still remain fully charged.
6. Carefully remove the compressor clutch field coil connector and wire lead from the connector bracket (2).
7. Remove the compressor shaft bolt (1). A band-type oil filter wrench or a strap wrench may be used to secure the clutch plate (2) during bolt removal.
CAUTION: Do not pry between the clutch plate and the pulley and bearing assembly to remove the clutch plate from the compressor shaft as this may damage the clutch plate.
NOTE: Use care not to lose any clutch shim(s) during removal of the clutch plate, as they may be reused during the clutch plate installation process.
8. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft (1). Remove the clutch plate and shim(s) (3) from the compressor shaft.
9. Using snap ring pliers 9764 or equivalent (2), remove the external snap ring (1) that secures the pulley and bearing assembly (3) to the front cover of the A/C compressor and remove the pulley and bearing assembly.
9. Using snap ring pliers 9764 or equivalent (1), remove the external snap ring (4) that secures the clutch field coil (2) to the front of the A/C compressor and remove the field coil.
INSTALLATION
1. Align the dowel pin on the back of the clutch field coil (2) with the hole in the compressor front cover (3) and position the clutch field coil onto the A/C compressor. Be certain that the clutch coil wire lead is properly routed so that it is not pinched between the A/C compressor and the field coil.
CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor.
NOTE: A new snap ring must be used to secure the clutch field coil to the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or to the left of the clutch field coil dowel pin location on the A/C compressor.
2. Using snap ring pliers 9764 or equivalent (1), install the snap ring (4) that secures the compressor clutch field coil to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented correctly.
CAUTION: Be certain to position the compressor clutch field coil wire lead so that it is not damaged during A/C compressor pulley and bearing installation.
CAUTION: When installing the pulley and bearing assembly, DO NOT mar the friction surfaces of the pulley or premature failure of the clutch will result.
3. Install the pulley and bearing assembly (1) onto the front of the A/C compressor. If necessary, tap the pulley gently with a block of wood (2) placed on the pulley friction surface.
CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor.
NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward.
4. Using snap ring pliers 9764 or equivalent (2), install the external snap ring (1) that secures the pulley and bearing assembly (3) to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove.
5. If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original shim(s) (3) on the compressor shaft (1) against the shoulder. If a new clutch plate and/or pulley and bearing assembly are being used, install a trial stack of shims 2.54 mm (0.010 in.) thick on the compressor shaft against the shoulder.
6. Install the clutch plate (2) onto the front of the A/C compressor.
7. Install the compressor shaft bolt (1). Tighten the bolt to 19 Nm (168 in.lbs.).
NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is correct. Spin the pulley before performing a final check of the air gap.
NOTE: On models with the clutch plate recessed into the pulley, use a 90� wire gap gauge to measure the clutch air gap. On other models, use a blade type feeler gauge to measure the air gap.
8. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly. The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024 in). If the air gap is not between specifications, add or subtract shims as needed until the desired air gap is obtained.
9. Carefully route the compressor clutch field coil wire lead behind the connector bracket (2).
10. Install the compressor clutch field coil connector (1) onto the connector bracket.
11. Connect the engine wire harness to the compressor clutch field coil connector.
12. Install the accessory drive belt.
13. Install the radiator fan and shroud assembly.
14. On 5.7L and 6.1L engine equipped vehicles, install the air cleaner housing and air intake hose.
15. Reconnect the negative battery cable.