Compressor Clutch Coil: Service and Repair

REMOVAL

NOTE: The compressor clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley, or coil replacement.

1. Disconnect and isolate the negative battery cable.
2. Remove the accessory drive belt.
3. Raise and support the vehicle.
4. Disconnect the engine wire harness connector from the clutch coil connector located on the top of the A/C compressor.
5. On models with the 3.3L and 3.8L engines, disengage the engine wire harness connector retainer from the bracket located on the top of the A/C compressor.
6. On models with the 2.4L, 2.5L and 2.8L engines, remove all of the compressor mounting bolts except the upper left (rear of the A/C compressor), which should only be loosened. Allow the front (pulley end) of the A/C compressor to tilt downward far enough to access the clutch for removal, then tighten the loosened upper left compressor mounting bolt.
7. On models with the 3.3L and 3.8L engines, remove the two bolts and two nuts that secure the A/C compressor to the engine. Disengage the mounting ear at the front of the A/C compressor from the stud on the engine, allow the front (pulley end) of the A/C compressor to tilt downward far enough to access the clutch for removal, then reinstall and tighten the upper left compressor mounting bolt.

A/C Compressor Shaft Bolt:

8. Remove the compressor shaft bolt. A band-type oil filter wrench or a strap wrench may be used to secure the clutch during bolt removal.

Clutch Plate And Shim(s):

9. Tap the clutch plate lightly with a plastic mallet to release it from the splines on the compressor shaft. Remove the clutch plate and shim(s) from the compressor shaft.

NOTE: Use care not to lose any of the shim(s).

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.

Clutch Pulley Snap Ring:

10. 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 A/C compressor, then slide the pulley off of the compressor.
11. Remove the screw that secures the clutch coil wire lead connector bracket and ground clip to the top of the compressor housing.

Remove Clutch Coil Snap Ring:

12. 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 A/C compressor.

INSTALLATION
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 A/C 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 A/C 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 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 the left of the clutch coil dowel pin location on the A/C 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 securely tighten the screw that secures the clutch coil pigtail wire connector bracket and ground clip to the top of the compressor housing.

Clutch Pulley - Installation:

4. Install the pulley onto the front cover of the A/C 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 A/C 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 A/C 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 2.54 mm (0.010 in.) thick on the compressor shaft against the shoulder.
7. Install the clutch plate onto the compressor shaft.

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 still correct. Spin the pulley before performing a final check of the air gap.

8. With the clutch plate assembly tight against the shim(s), measure the air gap between the clutch plate and the pulley face with feeler gauges. The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024 in.). If the proper air gap is not obtained, add or subtract shims as needed until the desired air gap is obtained.
9. Install the compressor shaft bolt. Tighten the bolt to 17.5 N.m (155 in. lbs.).
10. On models with the 2.4L, 2.5L and 2.8L engines, loosely install the four bolts that secure the A/C compressor to the mounting bracket on the engine (2.4L), or the cylinder block (2.5L/2.8L). Tighten the bolts to 28 N.m (21 ft. lbs.).
11. On models with the 3.3L and 3.8L engines, loosely install the two bolts and two nuts that secure the A/C compressor to the engine. Tighten each of the fasteners to 54 N.m (40 ft. lbs.) using the following sequence:
- The upper nut at the front of the compressor.
- The lower nut at the front of the compressor.
- The upper bolt at the rear of the compressor.
- The lower bolt at the rear of the compressor.
12. On models with the 3.3L and 3.8L engines, engage the retainer on the engine wire harness compressor clutch coil take out with the bracket on the top of the A/C compressor.
13. Connect the engine wire harness connector to the A/C compressor clutch coil.
14. Install the accessory drive belt.
15. Lower the vehicle.
16. Reconnect the negative battery cable.