Compressor Clutch

STANDARD PROCEDURE - A/C CLUTCH INSPECTION Examine the friction surfaces of the pulley and the clutch plate (2) for wear. The pulley and clutch plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft and nose area of the A/C compressor (1) for refrigerant oil. If refrigerant oil is found, the compressor shaft seal is leaking and the A/C compressor must be replaced. Check the pulley bearing for roughness or excessive leakage of grease. Replace the pulley and bearing assembly, if required.

ZEXEL A/C CLUTCH The A/C system on models equipped with the 2.8L engine use a Zexel DKS-17DS A/C compressor. The clutch assembly for this A/C compressor consists of a stationary electromagnetic coil (4), bearing and pulley assembly (3), shims (6) and a clutch plate (2) that is splined to the compressor shaft and secured by a bolt (1). These components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. The A/C clutch coil is pressed onto the front of this A/C compressor and cannot be serviced separately from the compressor. The A/C clutch bearing and pulley assembly is retained to the front of the compressor by a snap ring (5) and can be serviced separately.

VISTEON A/C CLUTCH The A/C system on models equipped with the 3.7L engine use the Visteon RS-18 A/C compressor. The clutch assembly for this A/C compressor consists of a stationary electromagnetic field coil (4), bearing and pulley assembly (3), shims (7) and a clutch plate (2), that is splined to the compressor shaft and secured by a bolt (1). These components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. The A/C clutch field coil is pressed onto the front of this A/C compressor and retained with a snap ring (6). The A/C clutch bearing and pulley assembly is also retained to the front of this compressor by a snap ring (5). The A/C clutch bearing and pulley assembly and the field coil can both be serviced separately.

The A/C system on models equipped with the 2.8L and 4.0L engine use a Zexel DKS-17DS A/C compressor. The clutch assembly for this A/C compressor consists of a stationary electromagnetic field coil (4), bearing and pulley assembly (3), shims (6), and a clutch plate (2) that is splined to the compressor shaft and secured by a bolt (1). These components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt.

The A/C clutch field coil is pressed onto the front of this A/C compressor and cannot be serviced separately from the compressor. The A/C clutch bearing and pulley assembly is retained to the front of the compressor by a snap ring (5) and can be serviced separately.

The A/C system on models equipped with the 3.7L engine use the Visteon HS-18 A/C compressor. The clutch assembly for this A/C compressor consists of a stationary electromagnetic field coil (4), bearing and pulley assembly (3), shims (7), and a clutch plate (2) that is splined to the compressor shaft and secured by a bolt (1). These components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt.

The A/C clutch field coil is pressed onto the front of this A/C compressor and retained with a snap ring (6). The A/C clutch bearing and pulley assembly is also retained to the front of this compressor by a snap ring (5). Both the A/C clutch bearing and pulley assembly and the field coil can be serviced separately.

The A/C compressor clutch components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. When the electromagnetic A/C clutch field coil is energized, it magnetically draws the clutch plate into contact with the clutch pulley and drives the compressor shaft. When the coil is not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley assembly.

A/C compressor clutch engagement is controlled by the powertrain control module (PCM) or the engine control module (ECM), depending on engine application. When the A/C-heater control is set to any A/C position, it sends a request signal on the CAN-B bus to the totally integrated power module (TIPM), which then transfers the request on the CAN-C Bus to the PCM/ECM, which determines if operating conditions are correct for A/C clutch engagement. When all operating conditions have been met, the PCM/ECM sends a signal on a dedicated hard-wired circuit back to the totally integrated power module (TIPM) to energize the internal A/C clutch high side driver. When energized, the A/C clutch high side driver provides battery current to the A/C clutch field coil.

The A/C clutch control system is diagnosed using a scan tool (refer to HEATING & AIR CONDITIONING - ELECTRICAL DIAGNOSTICS article or appropriate Engine ELECTRICAL DIAGNOSTICS article for more information).

The A/C compressor clutch components cannot be adjusted or repaired and must be replaced if found inoperative or damaged.

The A/C compressor clutch coil electrical circuit is controlled by the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) through the totally integrated power module (TIPM). See OPERATION. Begin testing of a suspected compressor clutch coil problem by performing the preliminary checks.

NOTE: The A/C clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley and bearing assembly, or coil replacement.

Examine the friction surfaces of the pulley and the clutch plate (2) for wear. The pulley and clutch plate should be replaced if there is excessive wear or scoring.

If the friction surfaces are oily, inspect the shaft and nose area of the A/C compressor (1) for refrigerant oil. If refrigerant oil is found, the compressor shaft seal is leaking and the A/C compressor must be replaced.

Check the pulley bearing for roughness or excessive leakage of grease. Replace the pulley and bearing assembly, if required.

After a new A/C compressor clutch has been installed, cycle the compressor clutch approximately 20 times (5 seconds on, then 5 seconds off). During this procedure, set the A/C-heater controls to the A/C Recirculation Mode, the blower motor in the highest speed position, and the engine speed at 1500 to 2000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability.

NOTE: The compressor clutch assembly can be serviced with the refrigerant system fully-charged.

1. Disconnect and isolate negative battery cable. 2. Remove the accessory drive belt. Refer to REMOVAL . 3. Disconnect the engine wire harness from the clutch field coil connector (4). 4. Remove the bolts that secure the A/C compressor (4) to the mounting bracket. See REMOVAL. 5. Remove the A/C compressor from the mounting bracket and support the compressor while servicing the clutch. 6. Using a strap wrench (1), remove the bolt (2) that secures the clutch plate (3) to the compressor shaft.

NOTE: The clutch plate can be removed from the compressor shaft by hand or, if required, pressed off with an 8 x 1.25 mm bolt.

NOTE: Clutch plate shim(s) may remain inside the hub of the clutch plate. Be sure to remove all of the shims from inside the hub or from the end of the compressor shaft.

7. Remove the clutch plate and shim(s) from the A/C compressor. If required, install a 8 x 1.25 mm bolt into the center of the clutch plate and turn the bolt clockwise until the clutch plate is completely removed from the A/C compressor.

Assembly To Front Of A/C Compressor

8. Using snap ring pliers (Special Tool 9764 or equivalent) (1), remove the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor (4).

NOTE: The pulley and bearing assembly can be removed from the compressor by hand or, if required, with a two jaw puller.

9. Remove the pulley and bearing assembly (1) from the front of the A/C compressor (2). If required, install a two jaw puller (3) and turn the puller center-bolt clockwise until the pulley and bearing assembly is completely removed.

10. Remove the screw (1) that secures the clutch field coil wire lead bracket (2) to the A/C compressor (3).

From Front Of A/C Compressor

11. Using compressor field coil remover (Special Tool 9354 in Kit 9349) (1) and a two jaw puller (2), remove the clutch field coil (3) from the front of the A/C compressor (4).

NOTE: The compressor clutch plate and pulley and bearing assembly and can be serviced with the refrigerant system fully-charged and with the A/C compressor installed on the engine.

NOTE: Typical A/C compressor and clutch assembly shown in illustrations.

1. Disconnect and isolate the negative battery cable. 2. Remove the coolant recovery container from the front of the engine compartment. Refer to REMOVAL . 3. Remove the radiator fan and shroud assembly. Refer to REMOVAL . 4. Remove the accessory drive belt. Refer to REMOVAL . 5. Disconnect the engine wire harness from the compressor clutch field coil connector (1) located on the top of the A/C compressor (5). 6. Remove the screw that secures the connector bracket (2) to the A/C compressor and position the bracket

and wire lead out of the way.

NOTE: A band-type oil filter wrench or a strap wrench may be used to hold the clutch plate from turning during compressor shaft bolt removal.

7. Hold the clutch plate (4) from turning and remove the compressor shaft bolt (3).

CAUTION: Do not pry between the clutch plate and the pulley and bearing assembly to remove the clutch plate from the compressor shaft as

this may damage the clutch plate.

NOTE: Use care not to lose any clutch shim(s) during removal of the clutch plate, as they may be reused during the clutch plate installation process.

8. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft (1) and remove the clutch plate and shim(s) (3).

NOTE: The pulley and bearing assembly can be removed from the compressor by hand or, if required, with a two jaw puller.

9. Using Snap Ring Pliers 9764 or equivalent (1), remove the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor (4). 10. Remove the pulley and bearing assembly from the front of the A/C compressor. If required, install a two jaw puller and turn the puller center-bolt clockwise until the pulley and bearing assembly is completely removed.

NOTE: Typical A/C compressor and clutch assembly shown in illustrations.

CAUTION: Be certain to position the compressor clutch field coil wire lead so that it is not damaged during A/C compressor pulley and bearing installation.

CAUTION: When installing the pulley and bearing assembly, DO NOT mar the friction surfaces of the pulley or premature failure of the clutch will result.

1. Install the pulley and bearing assembly (1) onto the front of the A/C compressor. If necessary, tap the pulley gently with a block of wood (2) placed on the pulley friction surface.

CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor.

NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward.

2. Using Snap Ring Pliers 9764 or equivalent (1), install the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor (4). Be certain that the snap ring is fully and properly seated in the groove.

3. If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original shim (s) (3) onto the compressor shaft (1). If a new clutch plate and pulley and bearing assembly are being used, install a trial stack of shims 1.50 mm (0.059 in.) thick onto the compressor shaft.

4. Install the clutch plate (4) onto the front of the A/C compressor (5). 5. Install the compressor shaft bolt (3). Tighten the bolt to 20 N.m (177 in. lbs.).

NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is correct. Spin the pulley before performing a final check of the air gap.

NOTE: On models with the clutch plate recessed into the pulley, use a 90° wire gap gauge to measure the clutch air gap. On other models, use a blade type feeler gauge to measure the air gap.

6. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly. The air gap should be between 0.30 - 0.60 mm (0.012 - 0.024 in.). If the air gap is not between specifications, add or subtract shims as needed until the correct air gap is obtained.

CAUTION: Be certain that the compressor clutch field coil wire lead is routed so that it is not pinched between the A/C compressor and the field coil connector bracket.

7. Carefully route the compressor clutch field coil wire lead and install the connector bracket (2) and retaining screw onto the A/C compressor. Tighten the screw to 4.3 N.m (38 in. lbs.). 8. Connect the engine wire harness to the compressor clutch field coil connector (1). 9. Install the accessory drive belt. Refer to INSTALLATION . 10. Install the radiator and fan shroud assembly. Refer to INSTALLATION . 11. Install the coolant recovery container. Refer to REMOVAL . 12. Reconnect the negative battery cable.

1. Position the A/C clutch field coil (1) squarely onto the front of the A/C compressor (2).

CAUTION: Position the A/C clutch field coil so that the coil positioning tabs and the wire harness lead are oriented in the correct direction. Failure to correctly position the field coil on the A/C compressor will result in field coil damage.

2. Align the field coil positioning tabs to the recessed area at the front of the A/C compressor and install the clutch field coil onto the compressor using a two jaw puller (3), compressor field coil installer (Special Tool 9352 in Kit 9349) (4) and the compressor field coil installer spacer (Special Tool 9353 in Kit 9349) (5).

3. Position the clutch field coil wire lead and bracket (2) to the A/C compressor (3) and install the screw (1) that secures the bracket to the compressor. Tighten the screw to 4 N.m (35 in. lbs.).

4. Align the pulley and bearing assembly (1) squarely onto the front of the A/C compressor (2).

NOTE: A distinct change of sound during the clutch pulley tapping process indicates that the pulley and bearing assembly has bottomed out against the compressor housing.

5. Using clutch pulley installer (Special Tool 9355 in Kit 9349) (3) and a hammer (4), install the pulley and bearing assembly onto the front of the A/C compressor. Tap the installer with a hammer until the pulley and bearing assembly has bottomed against the compressor housing.

Assembly To Front Of A/C Compressor

CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in clutch failure and severe damage to the A/C compressor.

NOTE: Install the snap ring with the beveled side of the snap ring facing outward.

6. Using snap ring pliers (Special Tool 9764 or equivalent) (1), install the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor (4). Make sure the snap ring is properly seated in the groove.

7. Verify that there is adequate clearance for the clutch field coil wire lead (1) between the housing of the A/C compressor (2) and the pulley and bearing assembly (3).

NOTE: When installing an original or a new clutch assembly, try the original shims first. When installing a clutch onto a compressor that previously did not have a clutch, use the 1.0, 0.50 and 0.13 millimeter (0.040, 0.020 and 0.005 inch) shims from the clutch hardware package which is provided with the new clutch.

8. Install the clutch shims onto the compressor shaft. 9. Using a strap wrench (4), install the bolt (5) that secures the clutch plate (6) to the A/C compressor. Hold the clutch plate stationary with the strap wrench and tighten the bolt to 15 N.m (133 in. lbs.).

10. Using 90° wire gauges (1), check the air gap between the clutch plate (2) and the pulley and bearing assembly (3). If the air gap is not between 0.35 to 0.65 millimeter (0.014 to 0.025 inch), add or subtract shims as required. 11. Position the A/C compressor onto the mounting bracket. 12. Install the bolts that secure the A/C compressor to the mounting bracket. See INSTALLATION. 13. Connect the engine wire harness to the compressor clutch field coil connector. 14. Install the accessory drive belt (Refer to BELT-ACCESSORY DRIVE ). 15. Reconnect the negative battery cable. 16. Perform the Clutch Break-in Procedure. See STANDARD PROCEDURE.

CONTROL-A/C HEATER

The A/C system on models equipped with the 2.8L and 4.0L engine use a Zexel DKS-17DS A/C compressor. The clutch assembly for this A/C compressor consists of a stationary electromagnetic field coil (4), bearing and pulley assembly (3), shims (6), and a clutch plate (2) that is splined to the compressor shaft and secured by a bolt (1). These components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt.

The A/C clutch field coil is pressed onto the front of this A/C compressor and cannot be serviced separately from the compressor. The A/C clutch bearing and pulley assembly is retained to the front of the compressor by a snap ring (5) and can be serviced separately.

The A/C system on models equipped with the 3.7L engine use the Visteon HS-18 A/C compressor. The clutch assembly for this A/C compressor consists of a stationary electromagnetic field coil (4), bearing and pulley assembly (3), shims (7), and a clutch plate (2) that is splined to the compressor shaft and secured by a bolt (1). These components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt.

The A/C clutch field coil is pressed onto the front of this A/C compressor and retained with a snap ring (6). The A/C clutch bearing and pulley assembly is also retained to the front of this compressor by a snap ring (5). Both the A/C clutch bearing and pulley assembly and the field coil can be serviced separately.

The A/C compressor clutch components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. When the electromagnetic A/C clutch field coil is energized, it magnetically draws the clutch plate into contact with the clutch pulley and drives the compressor shaft. When the coil is not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley assembly.

A/C compressor clutch engagement is controlled by the powertrain control module (PCM) or the engine control module (ECM), depending on engine application. When the A/C-heater control is set to any A/C position, it sends a request signal on the CAN-B bus to the totally integrated power module (TIPM), which then transfers the request on the CAN-C Bus to the PCM/ECM, which determines if operating conditions are correct for A/C clutch engagement. When all operating conditions have been met, the PCM/ECM sends a signal on a dedicated hard-wired circuit back to the totally integrated power module (TIPM) to energize the internal A/C clutch high side driver. When energized, the A/C clutch high side driver provides battery current to the A/C clutch field coil.

The A/C clutch control system is diagnosed using a scan tool (refer to HEATING & AIR CONDITIONING - ELECTRICAL DIAGNOSTICS article or appropriate Engine ELECTRICAL DIAGNOSTICS article for more information).

The A/C compressor clutch components cannot be adjusted or repaired and must be replaced if found inoperative or damaged.

The A/C compressor clutch coil electrical circuit is controlled by the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) through the totally integrated power module (TIPM). See OPERATION. Begin testing of a suspected compressor clutch coil problem by performing the preliminary checks.

NOTE: The A/C clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley and bearing assembly, or coil replacement.

Examine the friction surfaces of the pulley and the clutch plate (2) for wear. The pulley and clutch plate should be replaced if there is excessive wear or scoring.

If the friction surfaces are oily, inspect the shaft and nose area of the A/C compressor (1) for refrigerant oil. If refrigerant oil is found, the compressor shaft seal is leaking and the A/C compressor must be replaced.

Check the pulley bearing for roughness or excessive leakage of grease. Replace the pulley and bearing assembly, if required.

After a new A/C compressor clutch has been installed, cycle the compressor clutch approximately 20 times (5 seconds on, then 5 seconds off). During this procedure, set the A/C-heater controls to the A/C Recirculation Mode, the blower motor in the highest speed position, and the engine speed at 1500 to 2000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability.

NOTE: The compressor clutch assembly can be serviced with the refrigerant system fully-charged.

1. Disconnect and isolate negative battery cable. 2. Remove the accessory drive belt. Refer to REMOVAL . 3. Disconnect the engine wire harness from the clutch field coil connector (4). 4. Remove the bolts that secure the A/C compressor (4) to the mounting bracket. See REMOVAL. 5. Remove the A/C compressor from the mounting bracket and support the compressor while servicing the clutch. 6. Using a strap wrench (1), remove the bolt (2) that secures the clutch plate (3) to the compressor shaft.

NOTE: The clutch plate can be removed from the compressor shaft by hand or, if required, pressed off with an 8 x 1.25 mm bolt.

NOTE: Clutch plate shim(s) may remain inside the hub of the clutch plate. Be sure to remove all of the shims from inside the hub or from the end of the compressor shaft.

7. Remove the clutch plate and shim(s) from the A/C compressor. If required, install a 8 x 1.25 mm bolt into the center of the clutch plate and turn the bolt clockwise until the clutch plate is completely removed from the A/C compressor.

Assembly To Front Of A/C Compressor

8. Using snap ring pliers (Special Tool 9764 or equivalent) (1), remove the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor (4).

NOTE: The pulley and bearing assembly can be removed from the compressor by hand or, if required, with a two jaw puller.

9. Remove the pulley and bearing assembly (1) from the front of the A/C compressor (2). If required, install a two jaw puller (3) and turn the puller center-bolt clockwise until the pulley and bearing assembly is completely removed.

10. Remove the screw (1) that secures the clutch field coil wire lead bracket (2) to the A/C compressor (3).

From Front Of A/C Compressor

11. Using compressor field coil remover (Special Tool 9354 in Kit 9349) (1) and a two jaw puller (2), remove the clutch field coil (3) from the front of the A/C compressor (4).

NOTE: The compressor clutch plate and pulley and bearing assembly and can be serviced with the refrigerant system fully-charged and with the A/C compressor installed on the engine.

NOTE: Typical A/C compressor and clutch assembly shown in illustrations.

1. Disconnect and isolate the negative battery cable. 2. Remove the coolant recovery container from the front of the engine compartment. Refer to REMOVAL . 3. Remove the radiator fan and shroud assembly. Refer to REMOVAL . 4. Remove the accessory drive belt. Refer to REMOVAL . 5. Disconnect the engine wire harness from the compressor clutch field coil connector (1) located on the top of the A/C compressor (5). 6. Remove the screw that secures the connector bracket (2) to the A/C compressor and position the bracket

and wire lead out of the way.

NOTE: A band-type oil filter wrench or a strap wrench may be used to hold the clutch plate from turning during compressor shaft bolt removal.

7. Hold the clutch plate (4) from turning and remove the compressor shaft bolt (3).

CAUTION: Do not pry between the clutch plate and the pulley and bearing assembly to remove the clutch plate from the compressor shaft as

this may damage the clutch plate.

NOTE: Use care not to lose any clutch shim(s) during removal of the clutch plate, as they may be reused during the clutch plate installation process.

8. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft (1) and remove the clutch plate and shim(s) (3).

NOTE: The pulley and bearing assembly can be removed from the compressor by hand or, if required, with a two jaw puller.

9. Using Snap Ring Pliers 9764 or equivalent (1), remove the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor (4). 10. Remove the pulley and bearing assembly from the front of the A/C compressor. If required, install a two jaw puller and turn the puller center-bolt clockwise until the pulley and bearing assembly is completely removed.

NOTE: Typical A/C compressor and clutch assembly shown in illustrations.

CAUTION: Be certain to position the compressor clutch field coil wire lead so that it is not damaged during A/C compressor pulley and bearing installation.

CAUTION: When installing the pulley and bearing assembly, DO NOT mar the friction surfaces of the pulley or premature failure of the clutch will result.

1. Install the pulley and bearing assembly (1) onto the front of the A/C compressor. If necessary, tap the pulley gently with a block of wood (2) placed on the pulley friction surface.

CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor.

NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward.

2. Using Snap Ring Pliers 9764 or equivalent (1), install the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor (4). Be certain that the snap ring is fully and properly seated in the groove.

3. If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original shim (s) (3) onto the compressor shaft (1). If a new clutch plate and pulley and bearing assembly are being used, install a trial stack of shims 1.50 mm (0.059 in.) thick onto the compressor shaft.

4. Install the clutch plate (4) onto the front of the A/C compressor (5). 5. Install the compressor shaft bolt (3). Tighten the bolt to 20 N.m (177 in. lbs.).

NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is correct. Spin the pulley before performing a final check of the air gap.

NOTE: On models with the clutch plate recessed into the pulley, use a 90° wire gap gauge to measure the clutch air gap. On other models, use a blade type feeler gauge to measure the air gap.

6. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly. The air gap should be between 0.30 - 0.60 mm (0.012 - 0.024 in.). If the air gap is not between specifications, add or subtract shims as needed until the correct air gap is obtained.

CAUTION: Be certain that the compressor clutch field coil wire lead is routed so that it is not pinched between the A/C compressor and the field coil connector bracket.

7. Carefully route the compressor clutch field coil wire lead and install the connector bracket (2) and retaining screw onto the A/C compressor. Tighten the screw to 4.3 N.m (38 in. lbs.). 8. Connect the engine wire harness to the compressor clutch field coil connector (1). 9. Install the accessory drive belt. Refer to INSTALLATION . 10. Install the radiator and fan shroud assembly. Refer to INSTALLATION . 11. Install the coolant recovery container. Refer to REMOVAL . 12. Reconnect the negative battery cable.

1. Position the A/C clutch field coil (1) squarely onto the front of the A/C compressor (2).

CAUTION: Position the A/C clutch field coil so that the coil positioning tabs and the wire harness lead are oriented in the correct direction. Failure to correctly position the field coil on the A/C compressor will result in field coil damage.

2. Align the field coil positioning tabs to the recessed area at the front of the A/C compressor and install the clutch field coil onto the compressor using a two jaw puller (3), compressor field coil installer (Special Tool 9352 in Kit 9349) (4) and the compressor field coil installer spacer (Special Tool 9353 in Kit 9349) (5).

3. Position the clutch field coil wire lead and bracket (2) to the A/C compressor (3) and install the screw (1) that secures the bracket to the compressor. Tighten the screw to 4 N.m (35 in. lbs.).

4. Align the pulley and bearing assembly (1) squarely onto the front of the A/C compressor (2).

NOTE: A distinct change of sound during the clutch pulley tapping process indicates that the pulley and bearing assembly has bottomed out against the compressor housing.

5. Using clutch pulley installer (Special Tool 9355 in Kit 9349) (3) and a hammer (4), install the pulley and bearing assembly onto the front of the A/C compressor. Tap the installer with a hammer until the pulley and bearing assembly has bottomed against the compressor housing.

Assembly To Front Of A/C Compressor

CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in clutch failure and severe damage to the A/C compressor.

NOTE: Install the snap ring with the beveled side of the snap ring facing outward.

6. Using snap ring pliers (Special Tool 9764 or equivalent) (1), install the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor (4). Make sure the snap ring is properly seated in the groove.

7. Verify that there is adequate clearance for the clutch field coil wire lead (1) between the housing of the A/C compressor (2) and the pulley and bearing assembly (3).

NOTE: When installing an original or a new clutch assembly, try the original shims first. When installing a clutch onto a compressor that previously did not have a clutch, use the 1.0, 0.50 and 0.13 millimeter (0.040, 0.020 and 0.005 inch) shims from the clutch hardware package which is provided with the new clutch.

8. Install the clutch shims onto the compressor shaft. 9. Using a strap wrench (4), install the bolt (5) that secures the clutch plate (6) to the A/C compressor. Hold the clutch plate stationary with the strap wrench and tighten the bolt to 15 N.m (133 in. lbs.).

10. Using 90° wire gauges (1), check the air gap between the clutch plate (2) and the pulley and bearing assembly (3). If the air gap is not between 0.35 to 0.65 millimeter (0.014 to 0.025 inch), add or subtract shims as required. 11. Position the A/C compressor onto the mounting bracket. 12. Install the bolts that secure the A/C compressor to the mounting bracket. See INSTALLATION. 13. Connect the engine wire harness to the compressor clutch field coil connector. 14. Install the accessory drive belt (Refer to BELT-ACCESSORY DRIVE ). 15. Reconnect the negative battery cable. 16. Perform the Clutch Break-in Procedure. See STANDARD PROCEDURE.

CONTROL-A/C HEATER