Compressor Clutch Coil: Service and Repair
A/C COMPRESSOR CLUTCH/COILREMOVAL
NOTE: The A/C compressor clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley, or field coil replacement.
1. Disconnect and isolate the negative battery cable.
2. Remove the accessory drive belt.
3. Raise and support the vehicle.
4. Disconnect the engine wire harness from the compressor clutch field coil connector located on top of the A/C compressor.
5. Disengage the engine wire harness from the wiring bracket located near the front of the A/C compressor.
6. Disengage the compressor clutch field coil connector from the bracket located on top of the A/C compressor.
7. On models with the 3.5L engine, remove all of the compressor mounting bolts except the upper rear of the A/C compressor, which should only be loosened. Allow the front (pulley end) of the A/C compressor to tilt downward far enough to access the clutch for removal, then tighten the loosened upper rear compressor mounting bolt.
8. On models with the 3.8L engine, remove the two bolts and two nuts that secure the A/C compressor to the engine. Disengage the mounting ear at the front of the A/C compressor from the stud on the engine, allow the front (pulley end) of the A/C compressor to tilt downward far enough to access the clutch for removal, then reinstall and tighten the upper rear compressor mounting bolt.
A/C Compressor Shaft Bolt:
9. Remove the compressor shaft bolt. A band-type oil filter wrench or a strap wrench may be used to hold the A/C clutch plate during bolt removal.
Clutch Plate And Shim(s):
10. Tap the A/C clutch plate lightly with a plastic mallet to release it from the splines on the compressor shaft. Remove the clutch plate and shim(s) from the compressor shaft.
NOTE: Use care not to lose any of the shim(s).
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.
Clutch Pulley Snap Ring:
11. Using snap ring pliers, remove the snap ring that secures the pulley and bearing assembly to the front of the A/C compressor and remove the pulley and bearing assembly.
12. Remove the screw that secures the clutch field coil connector bracket to the top of the A/C compressor.
Remove Clutch Coil Snap Ring:
13. Using snap ring pliers, remove the snap ring that secures the compressor clutch field coil to the front of the A/C compressor and remove the field coil.
INSTALLATION
1. Align the dowel pin on the back of the clutch field coil with the hole in the compressor front cover and position the field coil onto the A/C compressor. Be certain that the clutch coil wire lead is properly oriented and routed so that it is not pinched between the compressor front cover and the clutch field coil.
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.
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.
2. Using snap ring pliers, install the snap ring that secures the clutch field coil to the front of 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 the left of the clutch coil dowel pin location on the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove.
3. Install and securely tighten the screw that secures the compressor clutch field coil connector bracket to the top of the A/C compressor.
Clutch Pulley - Installation:
4. Install the pulley and bearing assembly onto the front of the A/C 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 A/C compressor. The bevel side of the snap ring must face outward.
5. Using snap ring pliers, install the snap ring (bevel side facing outward) that secures the clutch pulley and bearing assembly to 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 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, install a trial stack of shims 2.54 mm (0.010 in.) thick on the compressor shaft against the shoulder.
7. Install the clutch plate onto the compressor shaft.
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 still correct. Spin the pulley before performing a final check of the air gap.
8. With the clutch plate assembly tight against the shim(s), measure the air gap between the clutch plate and the pulley face with a feeler gauge. The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024 in.). If the proper air gap is not obtained, add or subtract shims as needed until the desired air gap is obtained.
9. Install the compressor shaft bolt. Tighten the bolt to 17.5 N.m (155 in. lbs.).
10. Position the A/C compressor to its installed location.
11. On models with the 3.5L engine, loosely install the four bolts that secure the A/C compressor to the compressor mounting bracket. Tighten the bolts to 28 N.m (21 ft. lbs.) in the following sequence:
- 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
12. On models with the 3.8L engine, loosely install the two bolts and two nuts that secure the A/C compressor to the engine. Tighten each of the fasteners to 54 N.m (40 ft. lbs.) in the following sequence:
- The upper nut at the front of the compressor
- The lower nut at the front of the compressor
- The upper bolt at the rear of the compressor
- The lower bolt at the rear of the compressor
13. Install the compressor clutch field coil connector onto the connector bracket located on top of the A/C compressor.
14. Connect the engine wire harness to the compressor clutch field coil connector.
15. Install the engine wire harness lead onto the wiring bracket located near the front of the A/C compressor.
16. Install the accessory drive belt.
17. Lower the vehicle.
18. Reconnect the negative battery cable.