Compressor Clutch: Service and Repair
CLUTCH-A/C COMPRESSORREMOVAL
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 the negative battery cable.
2. Remove the accessory drive belt.
3. Disconnect the engine wire harness connector for the A/C compressor clutch coil from the clutch field coil wire harness connector on the top of the A/C compressor.
4. Remove the bolts that secure the A/C compressor to the engine and support the A/C compressor.
5. 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.
6. 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.
7. Using snap ring pliers (Special Tool C-4574 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, then slide the pulley and bearing assembly off of the A/C compressor.
8. Remove the screw that secures the clutch coil pigtail wire connector bracket and ground clip to the top of the compressor housing (3).
9. Using snap ring pliers (Special Tool C-4574 or equivalent) (1), remove the external snap ring (4) that secures the clutch field coil (2) to the front cover of the compressor housing, then slide the clutch field coil off of the A/C compressor.
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 harness is properly oriented and routed so that it is not pinched between the compressor front cover and the clutch 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 (Special Tool C-4574 or equivalent) (1), install the external snap ring (4) that secures the clutch field coil to the front cover of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented correctly.
3. Install the screw that secures the clutch field coil wire harness connector bracket and ground clip to the top of the compressor housing. Tighten the screw securely.
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.
4. Install the pulley and bearing assembly (1) onto the front cover 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.
5. Using snap ring pliers (Special Tool C-4574 or equivalent) (2), install the external snap ring (1) that secures the pulley and bearing assembly (3) to the front cover of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove.
6. 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.
7. Install the clutch plate (2) onto the compressor shaft.
8. Install the compressor shaft bolt (1). Tighten the bolt to 19 N.m (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.
9. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly faces with a feeler gauge. The air gap should be between specifications. If the proper air gap is not obtained, add or subtract shims as needed until the desired air gap is obtained.
10. Install the bolts that secure the A/C compressor to the engine.
11. Connect the engine wire harness connector to the A/C compressor clutch coil.
12. Install the accessory drive belt.
13. Reconnect the negative battery cable.