Compressor Clutch: Service and Repair

Air Conditioning Clutch Assembly Replacement

Special Tools
* 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. Refer to Drive Belt Replacement Service and Repair for the 2.4L engine or Drive Belt Replacement Service and Repair for the 3.5L engine.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
3. Remove the lower air deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement Radiator Air Lower Baffle and Deflector Replacement.





Note: Remove the 3 adjustable dowels from J 37872 .

Install three 5/16 X 1 inch bolts in place of the dowels.

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




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 M6 X 1.0 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.





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

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.





Caution: Refer to Fastener Caution Fastener Caution.

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

9. Install the clutch drive plate bolt.
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 Nm (106 lb in).

11. Install the lower air deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement Radiator Air Lower Baffle and Deflector Replacement.
12. Lower the vehicle.
13. Install the drive belt to the A/C compressor. Refer to Drive Belt Replacement Service and Repair for the 2.4L engine or Drive Belt Replacement Service and Repair for the 3.5L engine.
14. Leak test the fittings using the J 39400-A .