Thermal Limiting Fuse: Service and Repair

Compressor Thermal Protection Switch Replacement (L61)

Tools Required

J 44020 Terminal Repair Kit

Removal Procedure




1. Raise and support the vehicle. Refer to Vehicle Lifting.
2. Cut the wire harness leads (1) to the clutch coil.
3. Remove the electrical connector from the clutch coil bracket.




4. Remove the thermal protection switch (TPS) retainer bolt from the compressor.
5. Remove the TPS retainer from the compressor.
6. Remove the TPS assembly from the compressor. It may be necessary to gently pry the TPS with a flat bladed tool.

Installation Procedure





Important: To ensure proper routing and retention, be sure the new TPS assembly is cut to the same length as the original TPS assembly.

1. Measure and cut the new TPS assembly to the proper length.
2. Remove 9.5 mm (3/8 in) of insulation from the ends of the TPS assembly and the wire harness.
3. Position the stripped ends of wire in the appropriate splice sleeve found in J 44020.
4. Crimp the splices using an approved crimping tool.
5. Gently tug on the wires to ensure proper crimping.




6. Apply heat (1) to the splice joints until glue (2) flows from the splice sleeves.




7. Clean the TPS pocket of any foreign material.

Important: Use Saturn thermal conductive sealant P/N 22681632 to ensure the TPS functions properly.

8. Apply Saturn thermal conductive sealant P/N 22681632 to the TPS pocket.
9. Install the TPS to the TPS pocket on the compressor.
10. Remove any excess sealant from around the switch.
11. Install the TPS retainer to the compressor.

Notice: Refer to Fastener Notice.

12. Install the TPS retainer bolt to the compressor.

Tighten the bolt to 6 N.m (53 lb in).

13. Install the electrical connector to the clutch coil bracket.
14. Lower the vehicle.