A/C Compressor Clutch Replacement

REMOVAL
The refrigerant system can remain fully charged during compressor clutch, pulley, or coil replacement. Although the compressor assembly must be removed from its mounting, the compressor clutch can be service with the compressor in the vehicle.
1. Disconnect and isolate the battery negative cable.
2. Raise and support the vehicle.
3. Remove the serpentine drive belt. Refer to: "Engine, Cooling and Exhaust : Drive Belts, Mounts, Brackets and Accessories : Drive Belts : Service and Repair" Service and Repair
4. Disconnect the engine wire harness connector for the compressor clutch coil from the clutch coil pigtail wire connector on the top of the compressor.
5. On models with these engines, disengage the retainer on the engine wire harness compressor clutch coil take out from the bracket on the top of the compressor.
6. On models with these engines, remove the three screws and one nut that secure the compressor to the engine. Disengage the mounting ear at the front of the compressor from the stud on the engine, allow the front (pulley end) of the compressor to tilt downward far enough to access the clutch for removal, then reinstall and tighten the upper left compressor mounting screw.

Fig.13 Compressor Shaft Bolt And Clutch Plate:

7. Remove the compressor shaft bolt. If necessary, a band-type oil filter wrench or a strap wrench can be placed around the clutch plate to aid in bolt removal.

Fig.14 Clutch Plate And Shim(s):

8. Tap the clutch plate lightly with a plastic hammer and remove the clutch plate and shim(s) from the compressor shaft. Be certain not to lose the shim or shims.

CAUTION: Do not pry between the clutch plate unit and the pulley to remove the clutch plate from the compressor shaft as this may damage the clutch plate.

Fig.15 Remove Clutch Pulley Snap Ring:

9. Using snap ring pliers (Special Tool C-4574 or equivalent), remove the external snap ring that secures the pulley to the front cover of the compressor, then slide the pulley OFF of the compressor.
10. Remove the screw that secures the clutch coil pigtail wire connector bracket and ground clip to the top of the compressor housing.

Fig.16 Remove Clutch Coil Snap Ring:

11. Using snap ring pliers (Special Tool C-4574 or equivalent), remove the external snap ring that secures the clutch coil to the front cover of the compressor housing, then slide the clutch coil OFF of the compressor.

INSTALLATION
The refrigerant system can remain fully charged during compressor clutch, pulley, or coil replacement. Although the compressor assembly must be removed from its mounting, the compressor clutch can be service with the compressor in the vehicle.
1. Align the dowel pin on the back of the clutch coil with the hole in the compressor front cover, and position the clutch coil onto the compressor. Be certain that the clutch coil pigtail wires are properly oriented and routed so that they are not pinched between the compressor front cover and the clutch coil.

NOTE: A new snap ring must be used to secure the clutch coil to the compressor. The bevel side of the snap ring must face outward.

2. Using snap ring pliers (Special Tool C-4574 or equivalent), install the external snap ring that secures the clutch coil to the front cover of the compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or the left of the clutch coil dowel pin location on the compressor. Be certain that the snap ring is fully and properly seated in the groove.

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 compressor front cover.

3. Install and tighten the screw that secures the clutch coil pigtail wire connector bracket and ground clip to the top of the compressor housing.

Fig.17 Install Clutch Pulley:

4. Install the pulley onto the front cover of the compressor. If necessary, tap the pulley gently with a block of wood placed on the pulley friction surface.

CAUTION: Do not mar the friction surfaces of the pulley.

NOTE: A new snap ring must be used to secure the clutch pulley to the compressor. The bevel side of the snap ring must face outward.

5. Using snap ring pliers (Special Tool C-4574 or equivalent), install the external snap ring (bevel side facing outward) that secures the clutch pulley to the front cover of the compressor. Be certain that the snap ring is fully and properly seated in the groove.
6. If the original clutch plate and clutch pulley are to be reused, reinstall the original shim(s) on the compressor shaft against the shoulder. If a new clutch plate and/or clutch pulley are being used, install a trial stack of shims 1.0 mm (0.040 in.) thick on the compressor shaft against the shoulder.
7. Install the clutch plate onto the compressor shaft.
8. Install and tighten the compressor shaft nut. If necessary, a band-type oil filter wrench or a strap wrench can be placed around the clutch plate to aid in bolt tightening. Tighten the bolt to 17.5 Nm (155 in. lbs.).
9. If a new clutch plate and/or clutch pulley are being installed, the air gap between the clutch plate and clutch pulley must be checked. Refer to: "Compressor Clutch : Service and Repair" Service and Repair
10. On models with these engines only, loosely install the three screws and one nut that secure the compressor to the engine. Tighten each of the fasteners using the following sequence to 54 Nm (40 ft. lbs.).
- The upper screw at the rear of the compressor.
- The lower screw at the rear of the compressor.
- The lower screw at the front of the compressor.
- The upper nut at the front of the compressor.
11. On models with these engines only, engage the retainer on the engine wire harness compressor clutch coil take out with the bracket on the top of the compressor.
12. Reconnect the engine wire harness connector for the compressor clutch coil to the coil pigtail wire connector on the top of the compressor.
13. Reinstall the serpentine accessory drive belt onto the front of the engine. "Engine, Cooling and Exhaust : Drive Belts, Mounts, Brackets and Accessories : Drive Belts : Service and Repair" Service and Repair
14. Lower the vehicle.
15. Reconnect the battery negative cable.
16. If a new clutch plate and/or clutch pulley are being installed, the new clutch components must be burnished.Refer to: "Compressor Clutch : Service and Repair" Service and Repair