Compressor Clutch: Service and Repair
COMPRESSOR CLUTCH - ORURA(R) CLUTCHREMOVAL
IMPORTANT: It is not necessary to discharge the A/C system to service the A/C compressor clutch.
1. Remove accessory drive belt from compressor clutch pulley by rotating belt tensioner clockwise using a 14 mm or 9/16 in. wrench. Snap-On(TM) tool S8190A (or equivalent) can be used.
2. Disconnect A/C compressor clutch electrical connector.
IMPORTANT: The next 7 steps are only necessary if the vehicle is equipped with secondary air pump reaction system (AIR).
3. Remove nuts from combination valve studs.
4. Remove air hose.
5. Remove vacuum source hose. (There is no need to disconnect the internal vacuum hose for this procedure.)
6. Remove combination valve and gasket from rear air compressor bracket.
7. Position combination valve and gasket away from A/C compressor bracket.
8. Remove air pipe nuts from exhaust manifold studs.
9. Remove air pipe.
10. Remove rear A/C compressor-to-engine bracket bolts.
11. Remove front A/C compressor-to-engine bracket bolts.
NOTE: Ensure that A/C discharge line does not change position and/or loosen at the condenser connection due to moving discharge line. Failure to ensure a tight connection will result in a system refrigerant leak.
12. With A/C lines still attached, lift A/C compressor upward and install one front bolt through front engine bracket top hole and bottom rear mounting ear of A/C compressor. Tighten bolt so that the A/C compressor is supported by the bracket.
13. Position screwdriver between two vibration dampners on front of clutch face and remove clutch bolt.
IMPORTANT: Be careful not to lose shims inside of clutch drive plate opening when removing drive plate from compressor shaft.
14. Position flat blade screwdriver under clutch drive plate and pry out evenly to remove.
15. Using external snap ring pliers, remove the snap ring.
NOTE: Do not remove pulley without puller adapter. If A/C compressor shaft is pressed on, A/C compressor will be damaged.
16. Position the puller center tool SA9149AC-2 on the end of the A/C compressor shaft.
IMPORTANT: Make sure to hook the puller jaw behind the pulley.
17. Install three-jaw puller on A/C compressor pulley. Tighten the center bolt to remove pulley assembly.
IMPORTANT: To enable easier removal of screws, lightly tap on the end of the screwdriver with a plastic hammer.
18. Remove three A/C compressor clutch coil screws and remove A/C compressor clutch coil.
INSTALLATION
1. Position A/C compressor clutch coil so that electrical connector is aligned with indent in compressor front head.
2. Install three A/C compressor clutch coil screws.
Torque: 5 N.m (44 in-lbs)
3. Place thrust bearing and drive plate installer SA9149AC-3 on installation bolt and insert through center of pulley. Thread installation bolt into end of A/C compressor shaft and finger tighten.
4. Finger tighten nut on installation bolt to align pulley to A/C compressor. While holding end of bolt, tighten nut until pulley bottoms out on A/C compressor.
5. Loosen nut and remove pulley installation bolt.
6. Install snap ring with the tapered side out using snap ring pliers.
7. Install shims from old drive plate opening to new drive plate opening.
8. Position clutch drive plate on compressor shaft making sure the splines line up. Press shaft into place.
9. Position screwdriver between two vibration dampners on front of clutch face and install clutch bolt.
10. Install center bolt and tighten.
Torque: 13 N.m (115 in-lbs)
IMPORTANT: After tightening the center bolt, check to make sure that the pulley rotates smoothly by spinning it.
11. Check to make sure clutch clearance is 0.3 mm-0.6 mm (0.012 in-0.024 in.).
12. If necessary, adjust clearance by adding or removing shim(s) provided.Refer to clutch drive plate removal steps in the removal procedure to add or remove shims.
13. Remove front bracket-to-compressor bolt and position A/C compressor between brackets.
14. Install A/C compressor to front bracket with three bolts. Finger tighten bolts.
15. Install A/C compressor to rear bracket with three bolts. Tighten front and rear bolts.
Front bolts:
Torque: 49 N.m (36 ft-lbs)
Rear bolts:
Torque: 25 N.m (19 ft-lbs)
NOTE: Make sure gaskets are installed correctly or a leak will occur. If gaskets are removed from studs, replace with new gaskets. Installation steps must be performed in sequence.
IMPORTANT: The next 7 steps are only necessary if the vehicle is equipped with secondary air pump reaction system (AIR).
16. Install air pipe onto exhaust manifold studs.
17. Install air pipe into rear air compressor bracket slot.
18. Install combination valve studs into rear air compressor bracket through air pipe flange holes.
19. Install and torque nuts on combination valve studs.
Torque: 7 N.m (62 in-lbs)
20. Install and torque nuts on exhaust manifold studs.
Torque: 7 N.m (62 in-lbs)
21. Install vacuum source hose.
22. Install air hose.
23. Connect A/C compressor clutch electrical connector.
24. Install accessory drive belt.
25. Start engine and engage A/C compressor 10-15 cycles to break-in new A/C compressor clutch. This cycling of the A/C compressor will match drive plate and pulley surfaces.