Compressor Clutch: Service and Repair

Compressor Clutch Assembly Replacement (2.0L (LSJ))

Tools Required

* J 37872 Universal Spanner Wrench
* SA9149AC-8Snap Ring Pliers

Removal Procedure

1. Remove the compressor.






Important: Remove the 3 adjustable dowels from the Universal Spanner Wrench.

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

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




3. Remove the compressor clutch plate.




4. Remove the compressor pulley snap ring using SA9149AC-8.




5. Slide the compressor pulley off of the compressor.




6. Remove the compressor clutch coil snap ring using SA9149AC-8.




7. Slide the compressor clutch coil off of 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. Slide the compressor clutch coil onto the compressor.




3. Install the compressor clutch coil snap ring using SA9149AC-8.




4. Slide the compressor pulley onto the compressor.




5. Install the compressor pulley snap ring using SA9149AC-8.
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.






Important: 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.

Notice: Refer to Fastener Notice.




9. Make certain that the new drive plate bolt has colored adhesive on at least 5 threads. Install the clutch drive plate bolt. Use the J 37872 to hold the compressor clutch plate from turning.

Tighten the compressor clutch drive plate bolt to 12 N.m (106 lb in).

10. Install the compressor.
11. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
12. Leak test the fittings using the J 39400-A.