Compressor Clutch: Service and Repair

Compressor Clutch Assembly Replacement

Tools Required
* J 37872 - Compressor Clutch Holding Tool
* J 6083 - Snap Ring Pliers
* J 39400-A - Halogen Leak Detector

Removal Procedure

1. Remove the compressor. Refer to Air Conditioning Compressor Replacement (LZE, LZ4, LGD) (Service and Repair)Air Conditioning Compressor Replacement (LS4) (Service and Repair).

Note: Remove the three adjustable dowels from the J37872 Compressor Clutch Holding Tool.

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 - Compressor Clutch Holding Tool to hold the compressor clutch plate from turning.

3. Remove the compressor clutch plate from the compressor.

4. Remove the compressor pulley snap ring using the J 6083 - Snap Ring Pliers.

5. Remove the compressor pulley from the compressor.

6. Remove the compressor clutch coil snap ring using the J 6083 - Snap Ring Pliers.

7. 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 - Snap Ring Pliers.

4. Install the compressor pulley to the compressor.

5. Install the compressor pulley snap ring using the J 6083 - Snap Ring Pliers.
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).

Important: 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 to 12 Nm (106 lb in).
Use the J 37872 - Compressor Clutch Holding Tool to hold the compressor clutch plate from turning.
11. Install the compressor. Refer to Air Conditioning Compressor Replacement (LZE, LZ4, LGD) (Service and Repair)Air Conditioning Compressor Replacement (LS4) (Service and Repair).
12. Leak test the fittings using the J 39400-A - Halogen Leak Detector.