Compressor Clutch: Service and Repair

COMPRESSOR CLUTCH ASSEMBLY REPLACEMENT

TOOLS REQUIRED
- J 37872 Universal Spanner Wrench
- J 6083 Snap Ring Pliers
- J 39400-A Halogen Leak Detector

REMOVAL PROCEDURE
1. Remove the drive belt from the A/C compressor.
2. Raise and support the vehicle. Refer to Vehicle Lifting.
3. Remove the lower air deflector.

4. Remove and discard the compressor clutch plate bolt. Use the J 37872 to hold the compressor clutch plate from turning.

IMPORTANT: Remove the 3 adjustable dowels from J 37872.

Install three 5/16x1 inch bolts in place of the dowels.

5. Remove the compressor clutch plate from the compressor.

6. Remove the compressor pulley snap ring using the J 6083.

7. Remove the compressor pulley from the compressor.

8. Remove the compressor clutch coil snap ring using the J 6083.

9. Remove the compressor clutch coil from the compressor.

INSTALLATION PROCEDURE
1. Carefully clean the clutch plate bolt threads with a M6x1.0 tap. Carefully blow out debris with compressed air.

2. Install the compressor clutch coil to the compressor.

3. Install the compressor clutch coil snap ring using the J 6083.

4. Install the compressor pulley to the compressor.

5. Install the compressor pulley snap ring using the J 6083.
6. Place a small amount of oil on the 0.4 mm (0.016 in) air gap shim and place inside the clutch drive plate.

7. Install the compressor clutch plate to the compressor.

8. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.3-0.6 mm (0.012-0.024 in) air gap.

IMPORTANT: Make certain that the drive plate does not drag against the pulley when the pulley is rotated.

9. Install the clutch drive plate bolt.

NOTE: Refer to Fastener Notice.

IMPORTANT: Make certain that the new drive plate bolt has colored adhesive on at least 5 threads.

10. Tighten the compressor clutch drive plate bolt.Use the J 37872 to hold the compressor clutch plate from turning.

Tighten the bolt to 12 N.m (106 lb in).

11. Install the lower air deflector.
12. Lower the vehicle.
13. Install the drive belt to the A/C compressor.
14. Leak test the fittings using the J 39400-A.