Zexel A/C Compressor

ZEXEL A/C COMPRESSOR

NOTE: The compressor clutch plate and pulley and bearing assembly and can be serviced with the refrigerant system fully-charged and with the A/C compressor installed on the engine.

NOTE: Typical A/C compressor and clutch assembly shown in illustrations.





1. Disconnect and isolate the negative battery cable.
2. Remove the coolant recovery container from the front of the engine compartment Coolant Recovery Container - Removal.
3. Remove the radiator fan and shroud assembly Radiator Fan - Removal.
4. Remove the accessory drive belt Accessory Drive Belt - Removal.
5. Disconnect the engine wire harness from the compressor clutch field coil connector (1) located on the top of the A/C compressor (5).
6. Remove the screw that secures the connector bracket (2) to the A/C compressor and position the bracket and wire lead out of the way.

NOTE: A band-type oil filter wrench or a strap wrench may be used to hold the clutch plate from turning during compressor shaft bolt removal.

7. Hold the clutch plate (4) from turning and remove the compressor shaft bolt (3).




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.

8. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft (1) and remove the clutch plate and shim(s) (3).




NOTE: The pulley and bearing assembly can be removed from the compressor by hand or, if required, with a two jaw puller.

9. Using Snap Ring Pliers 9764 or equivalent (1), remove the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor (4).
10. Remove the pulley and bearing assembly from the front of the A/C compressor. If required, install a two jaw puller and turn the puller center-bolt clockwise until the pulley and bearing assembly is completely removed.