A/C Compressor Clutch Replacement

REMOVAL
The refrigerant system can remain fully charged during compressor clutch, pulley, or coil replacement. Although the compressor assembly must be removed from its mounting, the compressor clutch can be service with the compressor in the vehicle.
1. Disconnect and isolate the battery negative cable.
2. Remove the radiator fan assembly.
3. Remove the serpentine drive belt.
4. Disconnect the engine wire harness connector for the compressor clutch coil from the clutch coil wire harness connector on the top of the compressor.
5. Disengage the retainer on the engine wire harness compressor clutch coil lead from the bracket on the top of the compressor.
6. Remove the four bolts that secure the compressor to the mounting bracket and support the compressor.
7. Raise and support the vehicle.
8. Remove the underside compressor splash shield push pins and the splash shield.
9. Remove the four A/C compressor mount bolts and remove the compressor mount from the engine.

Compressor Shaft Bolt And Clutch Plate:

Clutch Plate And Shim(s):

10. Allow the front (pulley end) of the compressor to tilt downward far enough to access the clutch for removal, then remove the compressor shaft bolt. If necessary, a band-type oil filter wrench or a strap wrench can be placed around the clutch plate to aid in bolt removal.
11. Tap the clutch plate lightly with a plastic hammer and remove the clutch plate and shim(s) from the compressor shaft. Be certain not to lose the shim or shims.

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.

Remove Clutch Pulley Snap Ring:

12. 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 compressor, then slide the pulley off of the compressor.
13. Remove the screw that secures the clutch coil wire harness connector bracket and ground clip to the top of the compressor housing.

Remove Clutch Coil Snap Ring:

14. Using snap ring pliers (Special Tool C-4574 or equivalent), remove the external snap ring that secures the dutch coil to the front cover of the compressor housing, then slide the clutch coil off of the compressor.

INSTALLATION
The refrigerant system can remain fully charged during compressor clutch, pulley, or coil replacement. Although the compressor assembly must be removed from its mounting, the compressor clutch can be service with the compressor in the vehicle.
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 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 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 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 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 tighten the screw that secures the clutch coil wire harness connector bracket and ground clip to the top of the compressor housing.

Install Clutch Pulley:

4. Install the pulley onto the front cover of the 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 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 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,
8. Install and tighten the compressor shaft bolt. If necessary, a band-type oil filter wrench or a strap wrench can be placed around the clutch plate to aid in bolt tightening. Tighten the bolt to 17.5 Nm (155 in. lbs.).
9. If a new clutch plate and/or clutch pulley are being installed, the air gap between the clutch plate and clutch pulley must be checked.
10. Install the A/C compressor mount to the engine.
11. Install the four A/C compressor mount bolts to the engine. Two to the engine block and two to the oil pan. Torque the bolts to 115 Nm (85 ft. lbs.).
12. Position the A/C compressor to the mounting bracket.
13. Install the underside compressor splash shield and the push pin fasteners.
14. Lower the vehicle.
15. Loosely install the four bolts that secure the compressor to the engine. Tighten each of the bolts using the following sequence to 33 Nm (25 ft. lbs.).
- The upper bolt at the front of the compressor.
- The lower bolt at the front of the compressor.
- The upper bolt at the rear of the compressor.
- The lower bolt at the rear of the compressor.

16. Engage the retainer on the engine wire harness compressor clutch coil take out with the bracket on the top of the compressor.
17. Reconnect the engine wire harness connector for the compressor clutch coil to the coil wire harness connector on the top of the compressor.
18. Reinstall the serpentine accessory drive belt onto the front of the engine.
19. Install the radiator fan assembly.
20. Reconnect the battery negative cable.
21. If a new clutch plate and/or clutch pulley are being installed, the new clutch components must be burnished.