Compressor Clutch: Service and Repair

COMPRESSOR CLUTCH

TOOLS REQUIRED
^ J 25031-A Puller, Three Jaw
^ J 45267 A/C Clutch Holding Tool
^ J 45504 Clutch Pulley Installer

REMOVAL
1. Remove compressor from vehicle.




2. Use A/C Clutch Holding Tool J 45267 to hold disk & hub assembly. Remove clutch nut and disk & hub assembly.




3. Remove the spacer.




4. Remove the pulley snap ring.




5. Using Puller, Three Jaw J 25031-A if necessary, remove the A/C Clutch Pulley.




6. Remove thermal switch.
6.1 Remove bolt and hold down bracket.
6.2 Lift out the thermal switch while lightly twisting and pulling up on the sensor.
6.3 It may be necessary to pry up lightly with a small screwdriver.




7. Remove field coil snap ring.
8. Remove A/C clutch field coil.

INSTALLATION

1. Clean A/C clutch field coil and pulley mounting surfaces.




2. Install A/C clutch field coil.




3. Install field coil snap ring with the bevel side out.

NOTE: It is important to use Saturn Sealant P/N 22681632 as it is a thermal conductive material. Failure to use this sealant may affect the function of the switch.




4. Install thermal switch.
4.1 Clean thermal switch pocket if necessary.
4.2 Install thermal switch sealant in switch pocket, approximately the size of a pea.
4.3 Install thermal switch pushing into place and welting out sealant, while holding in place. Wipe away any excess.
4.4 Install hold down bracket and bolt.

Torque:
Hold Down Bracket and Bolt: 6 N.m (53 in. lbs.)

IMPORTANT: The A/C clutch bearing and pulley is a slip fit on the compressor. If correctly aligned it should slip on easily. If difficulty is encountered, install using pulley replacer tool.




5. Use Clutch Pulley Installer J 45504 if necessary, align clutch bearing/pulley assembly over hub and gently tap to install.




6. Install pulley snap ring bevel side out.




7. Install spacer.

NOTE: Make sure to align the block tooth on disk and hub assembly with groove in shaft.




8. Aligning disk & hub assembly block tooth with groove in shaft, install drive plate and nut (at this point, use the old nut to check clearances).




9. Using a feeler gauge, check to make sure clearance is 0.35-0.75 mm (0.014-0.030 in.).
10. If necessary, adjust clearance by adding or subtracting clutch hub spacers.




11. Once the correct air gap is obtained, install new clutch nut and tighten.

Torque:
Clutch Nut: 719 N.m (14 ft. lbs.)

12. Install compressor.