Compressor Clutch: Service and Repair
Air Conditioning Clutch Assembly Replacement (LAP)
Special Tools
* J 6083 - External Snap Ring Pliers
* J 37872 - Universal Spanner Wrench
* J 41816 - Crankshaft Balancer Remover
* J 39400-A - Halogen Leak Detector
For equivalent regional tools, refer to Special Tools (Heating, Ventilation, and Air Conditioning)
Removal Procedure
Note: Cap or tape the A/C compressor ports to ensure:
* Contamination or debris does not enter the A/C compressor.
* PAG oil is not lost once the A/C compressor is fixed into position.
1. Remove the A/C compressor from the vehicle. Refer to Air Conditioning Compressor Replacement (Removal and Replacement).
2. Mount the A/C compressor in a compressor stand or other suitable support fixture.
3. Remove the A/C compressor clutch assembly wiring harness retaining screws (1).
4. Using J 37872 - Universal Spanner Wrench to hold the hub assembly, remove the clutch plate retaining nut.
Note: Do not drop, lose or misplace the clutch shim from the A/C compressor shaft when removing the clutch.
5. Remove the clutch plate from the A/C compressor.
6. Use J 6083 - External Snap Ring Pliers to remove the pulley snap ring.
Note: Do not press on the A/C compressor shaft or compressor damage could occur.
7. Use an appropriate sized impact socket sized to sit on the compressor hub to protect the compressor shaft during pulley removal.
8. Use J 41816 - Crankshaft Balancer Remover to remove the hub assembly.
9. Use J 6083 - External Snap Ring Pliers to remove the coil snap ring.
10. Remove the clutch coil.
Note: Do not make contact with the A/C compressor shaft threads or damage the lip seal during shaft seal, felt wick, removal.
11. Using a small flat-bladed object, gently pry up on the shaft seal, felt wick, retainer and remove.
Installation Procedure
1. Using an appropriate sized socket to seat on the shaft seal (felt wick) outer retainer, install the shaft seal (felt wick) into the A/C compressor. The retainer should be flush with the housing.
2. Ensure that the all mounting surfaces and/or threads on the A/C compressor and clutch assembly are completely free of debris and contamination prior to reassembly.
Note: Align the dimple on the clutch coil with the notch in the A/C compressor casting to ensure proper orientation. Failure to align the clutch coil assembly will cause the snap ring retainer not to seat properly.
3. Install the clutch coil.
Note: Ensure that the clutch coil snap ring is fully seated within the bore.
4. Use J 6083 - External Snap Ring Pliers to install the coil snap ring.
Note: Do not press on the seal, pulley or outer bearing race.
5. Using an appropriate sized impact socket to seat on the inner bearing race, install the clutch pulley onto the A/C compressor using a hydraulic press.
Note: Ensure that the clutch pulley snap ring is fully seated within the bore.
6. Use J 6083 - External Snap Ring Pliers to install the pulley snap ring.
Caution: Refer to Fastener Caution (Fastener Caution).
7. Install the A/C compressor clutch assembly wiring harness retaining screws (1) and tighten 2.3 Nm (22 lb in).
8. Install the previously used clutch shim if removed from the A/C compressor shaft.
9. Install the clutch plate onto the A/C compressor.
10. Install the ORIGINAL clutch plate retaining nut and using the J 37872 - Universal Spanner Wrench and tighten 25 Nm (18 lb ft).
Note: Make certain that the clutch plate does not drag or interfere with the pulley when rotated.
11. Measure the air gap between the clutch plate and the clutch pulley. The air gap should be 0.3-0.7 mm (0.012-0.028 in). If the air gap is not within specification, remove shaft nut and clutch plate and use an alternate shim included in the service kit to achieve the proper air gap.
12. Remove the ORIGINAL clutch plate retaining nut and install the NEW nut provided in the kit and tighten 25 Nm (18 lb ft).
13. Remove the A/C compressor from the compressor stand or other suitable support fixture and remove the cap or tape from the A/C compressor ports.
14. Install the A/C compressor to the vehicle. Refer to Air Conditioning Compressor Replacement (Removal and Replacement).
15. Leak test the fittings using the J 39400-A - Halogen Leak Detector.