Minor Compressor Repair Procedures
Unidamp(R) ClutchREMOVAL
IMPORTANT: It is not necessary to discharge the A/C system to service the A/C compressor clutch.
1. Remove accessory drive belt from compressor clutch pulley by rotating belt tensioner clockwise using a 14 mm or 9/16 in. wrench. Snap-On(TM) tool S8190A (or equivalent) can be used.
2. Disconnect A/C compressor clutch electrical connector.
IMPORTANT: Steps 3 through 9 are only necessary if the vehicle is equipped with secondary air pump reaction system (AIR).
3. Remove nuts from combination valve studs.
4. Remove air hose.
5. Remove vacuum source hose. (There is no need to disconnect the internal vacuum hose for this procedure.)
6. Remove combination valve and gasket from rear air compressor bracket.
7. Position combination valve and gasket away from A/C compressor bracket.
8. Remove air pipe nuts from exhaust manifold studs.
9. Remove air pipe.
10. Remove rear A/C compressor-to-engine bracket bolts.
11. Remove front A/C compressor-to-engine bracket bolts.
NOTICE: Ensure that A/C discharge line does not change position and/or loosen at the condenser connection due to moving discharge line. Failure to ensure a tight connection will result in a system refrigerant leak.
12. With A/C lines still attached, lift A/C compressor upward and install one front bolt through front engine bracket top hole and bottom rear mounting ear of A/C compressor. Tighten bolt so that the A/C compressor is supported by the bracket.
13. Install clutch drive plate holder tool SA951OAC, and remove drive plate center bolt.
14. Remove drive plate holder tool and completely thread clutch drive plate remover sleeve SA9506AC into center of drive plate.
15. Thread drive plate remover bolt into sleeve. While holding clutch drive plate remover sleeve, tighten drive plate remover bolt to remove drive plate.
IMPORTANT: Be careful not to lose the shims when removing drive plate from compressor shaft.
16. Using external snap ring pliers, remove the snap ring.
NOTICE: Do not remove pulley without puller adapter. If A/C compressor shaft is pressed on, A/C compressor will be damaged.
17. Position the puller center tool SA9149AC-2 on the end of the A/C compressor shaft.
18. Install three-jaw puller on A/C compressor pulley. Tighten the center bolt to remove pulley assembly.
IMPORTANT: Make sure to hook the puller jaw behind the pulley.
19. Remove three A/C compressor clutch Coil screws and remove A/C compressor clutch coil.
IMPORTANT: To enable easier removal of screws, lightly tap on the end of the screwdriver with a plastic hammer.
INSTALLATION
1. Position A/C compressor clutch coil so that electrical connector is aligned with indent in compressor front head.
2. Install three A/C compressor clutch coil screws.
Torque: 5 N.m (44 in-lbs)
3. Place thrust bearing and drive plate installer SA9149AC-3 on installation bolt and insert through center of pulley. Thread installation bolt into end of A/C compressor shaft and finger tighten.
4. Finger tighten nut on installation bolt to align pulley to A/C compressor. While holding end of bolt, tighten nut until pulley bottoms out on A/C compressor.
5. Loosen nut and remove pulley installation bolt.
6. Install snap ring with the tapered side out using snap ring pliers.
7. Place thrust bearing on installation bolt. Insert installation bolt through drive plate.
8. Install shims removed from old drive plate over end of installation bolt. Make sure to install the same number of shims that were removed.
9. Thread installation bolt into A/C compressor shaft.
10. While holding the end of the installation bolt, tighten nut to press drive plate onto A/C compressor shaft. Tighten until drive plate bottoms out.
IMPORTANT: Make sure splines are engaged by rotating drive plate back-and-forth before tightening nut.
11. Loosen installation b6lt nut and remove installation bolt.
12. Install clutch drive plate holder tool SA9510AC.
13. Install center bolt and tighten.
Torque: 13 N.m (115 in-lbs)
IMPORTANT: After tightening the center bolt, check to make sure that the pulley rotates smoothly by spinning it.
14. Check to make sure clutch clearance is 0.5 mm-0.7 mm (0.018 in-0.030 in.).
15. If necessary, adjust clearance by adding shim(s) provided. Refer to steps 6 through 8 of Removal procedure to remove drive plate, then after installing shim(s), refer to steps 7 through 14 to install drive plate.
16. Remove front bracket-to-compressor bolt and position A/C compressor between brackets.
17. Install A/C compressor to front bracket with three bolts. Finger tighten bolts.
18. Install A/C compressor to rear bracket with three bolts. Tighten front and rear bolts.
Front bolts:
Torque: 49 N.m (36 ft-lbs)
Rear bolts:
Torque: 25 N.m (19 ft-lbs)
NOTICE: Make sure gaskets are installed correctly or a leak will occur. If gaskets are removed from studs, replace with new gaskets. Installation steps must be performed in sequence.
IMPORTANT: Steps 19 through 25 are only necessary if the vehicle is equipped with secondary air pump reaction system (AIR).
19. Install air pipe onto exhaust manifold studs.
20. Install air pipe into rear air compressor bracket slot.
21. Install combination valve studs into rear air compressor bracket through air pipe flange holes.
22. Install and torque nuts on combination valve studs.
Torque: 7 N.m (62 in-lbs)
23. Install and torque nuts on exhaust manifold studs.
Torque: 7 N.m (62 in-lbs)
24. Install vacuum source hose.
25. Install air hose.
26. Connect A/C compressor clutch electrical connector.
27. Install accessory drive belt.
28. Start engine and engage A/C compressor 10-15 cycles to break-in new A/C compressor clutch. This cycling of the A/C compressor will match drive plate and pulley surfaces.