Compressor Clutch Coil: Service and Repair

REMOVAL

NOTE:
- The compressor clutch assembly can be serviced with the refrigerant system fully-charged.
- Typical A/C compressor shown in illustrations.

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 clutch field coil connector located on the top of the A/C compressor.
5. On models with the 3.3L and 3.8L engines, disengage the engine wire harness connector retainer from the bracket located on the top of the A/C compressor.
6. On models with the 2.4L, 2.5L and 2.8L engines, remove all of the compressor mounting bolts except the upper left (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 left compressor mounting bolt.
7. On models with the 3.3L and 3.8L engines, 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 left compressor mounting bolt.
8. Carefully remove the compressor clutch field coil connector and wire lead from the connector bracket.

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 secure the clutch during bolt removal.

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.

Clutch Plate And Shim(s):

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

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.

Remove Clutch Coil Snap Ring:

12. Using snap ring pliers, remove the snap ring that secures the 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 compressor clutch field coil with the hole in the front of the A/C compressor and position the field coil onto the compressor. Be certain that the compressor clutch field coil wire lead is properly routed so that it is not pinched between the A/C compressor and the field coil.

CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor.

NOTE: A new snap ring must be used to secure the compressor clutch field coil to 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 to the left of the field coil dowel pin location on the A/C compressor.

2. Using snap ring pliers, install the snap ring that secures the clutch field coil to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented correctly.

CAUTION:
- Be certain to position the compressor clutch field coil wire lead so that it is not damaged during A/C compressor pulley and bearing installation.
- When installing the pulley and bearing assembly, DO NOT mar the friction surfaces of the pulley or premature failure of the clutch will result.

Clutch Pulley Installation:

3. 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: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor.

NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward.

4. Using snap ring pliers, install the snap ring that secures the 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.
5. If the original clutch plate and pulley and bearing assembly are to be reused, reinstall the original shim(s) onto the compressor shaft. If a new clutch plate and pulley and bearing assembly are being used, install a trial stack of shims 2.54 mm (0.010 in.) thick onto the compressor shaft.
6. Install the clutch plate onto the front of the A/C compressor.
7. Install the compressor shaft bolt. Tighten the bolt to 19 N.m (168 in. lbs.).

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 correct. Spin the pulley before performing a final check of the air gap.
- On models with the clutch plate recessed into the pulley, use a 90° wire gap gauge to measure the clutch air gap. On other models, use a blade type feeler gauge to measure the air gap.

8. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly. The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024 in.). If the air gap is not between specifications, add or subtract shims as needed until the correct air gap is obtained.

CAUTION: Be certain that the compressor clutch field coil wire harness is properly routed so that it is not pinched between the A/C compressor and the field coil connector bracket.

9. Carefully route the compressor clutch field coil wire lead behind the connector bracket.
10. Install the compressor clutch field coil connector onto the connector bracket.
11. On models with the 2.4L, 2.5L and 2.8L engines, loosely install the four bolts that secure the A/C compressor to the mounting bracket on the engine (2.4L), or the cylinder block (2.5L/2.8L). Tighten the bolts to 28 N.m (21 ft. lbs.).
12. On models with the 3.3L and 3.8L engines, 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.) using 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. On models with the 3.3L and 3.8L engines, engage the retainer on the engine wire harness compressor clutch coil take out with the bracket on the top of the A/C compressor.
14. Connect the engine wire harness to the compressor clutch field coil connector.
15. Install the accessory drive belt.
16. Lower the vehicle.
17. Reconnect the negative battery cable.