Sanden A/C Compressor

REMOVAL

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 mounting bracket and support the A/C compressor.
5. Insert the two pins of the spanner wrench (Special Tool C-4489 or equivalent) (2) into the holes of the clutch plate (1). Hold the clutch plate stationary and remove the nut.




6. Remove the clutch plate and shims.
7. Using snap ring pliers (Special Tool C-4574 or equivalent) (2), remove the snap ring that secures the pulley and bearing assembly (1).




8. Install the lip of the pulley and bearing puller (Special Tool C-6141-1 or equivalent) (1) into the snap ring groove of the pulley and bearing assembly and install the shaft protector (Special Tool C-6141-2 or equivalent) (2).




CAUTION: Do not apply excessive force to the end of the compressor shaft with the puller center bolt or damage to the shaft may occur.

9. Install the puller through-bolts (Special Tool C-6461 or equivalent) through the puller flange (2) and into the puller jaws (1). Turn the puller center bolt clockwise until the pulley and bearing assembly is free.




10. Remove the screw and retainer (3) from the wire harness lead (2) of the clutch field coil (1).




11. Using snap ring pliers (Special Tool C-4574 or equivalent) (2), remove the snap ring that secures the clutch field coil (1) and remove the field coil.

INSTALLATION

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.




1. Install the clutch field coil (1) and using snap ring pliers (Special Tool C-4574 or equivalent) (2), install the snap ring that secures the field coil to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove.




2. Install the retainer and screw (3) over the wire harness lead (2) of the clutch field coil (1) and onto the A/C compressor. Tighten the screw to 2.2 N.m (20 in.lbs.).




3. Position the pulley and bearing assembly (1) squarely onto the front of the A/C compressor.

NOTE: Thread the installer fully onto the compressor shaft. Turn the installer nut until the pulley and bearing assembly is fully seated.




4. Using installer (Special Tool C-6871 or equivalent) (2), install the pulley and bearing assembly.

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 snap ring that secures the pulley and bearing assembly (1) onto the front 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 (1) and pulley and bearing assembly are to be reused, reinstall the original shim(s) onto the compressor shaft. If a new clutch plate and/or pulley and bearing assembly are being used, install a 1.0, 0.50, and 0.13 millimeter (0.040, 0.020, and 0.005 inch) shims from the new clutch hardware package that is provided with the new clutch.
7. Install the clutch plate onto the compressor shaft.
8. Insert the two pins of the spanner wrench (Special Tool C-4489 or equivalent) (2) into the holes of the clutch plate (1). Hold the clutch plate stationary and install the nut that secures the clutch plate. Tighten the nut to 20 N.m (15 ft.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 mounting bracket.
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.