LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 726 (Heating, Ventilation, And Air Conditioning) >> Repair Instructions >> Compressor Clutch Assembly Replacement (LE5, L61) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2008 Pontiac G5 and 2008 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Installing A/C Compressor Shaft Seal
    GM2000970Courtesy of GENERAL MOTORS CORP.
  1. Using an appropriate sized socket to seat on the shaft seal (felt wick) outer retainer, install the shaft seal (felt wick) into the A/C compressor. The retainer should be flush with the housing.
  2. Ensure that the all mounting surfaces and/or threads on the A/C compressor and clutch assembly are completely free of debris and contamination prior to reassembly.
    3. Fig 2: View Of A/C Compressor Clutch Coil
    GM2000964Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Align the dimple on the clutch coil with the notch in the A/C compressor casting to ensure proper orientation. Failure to align the clutch coil assembly will cause the snap ring retainer not to seat properly.
  3. Install the clutch coil.
    4. Fig 3: View Of A/C Compressor Clutch Coil Snap Ring
    GM2000960Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure that the clutch coil snap ring is fully seated within the bore.
  4. Use J 6083  to install the coil snap ring. See Special Tools .
    5. Fig 4: Pressing Pulley Onto Compressor Shaft
    GM2000975Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not press on the seal, pulley or outer bearing race.
  5. Using an appropriate sized impact socket to seat on the inner bearing race, install the clutch pulley onto the A/C compressor using a hydraulic press.
    6. Fig 5: View Of A/C Compressor Pulley Snap Ring
    GM2000953Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure that the clutch pulley snap ring is fully seated within the bore.
  6. Use J 6083  to install the pulley snap ring. See Special Tools .
    7. Fig 6: Identifying A/C Compressor Clutch Assembly Wiring Harness Retaining Screws
    GM2000939Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  7. Install the A/C compressor clutch assembly wiring harness retaining screws (1).

    Tighten:  Tighten the screws to 2.3 N.m (22 lb in).

  8. Install the previously used clutch shim if removed from the A/C compressor shaft.
    9. Fig 7: Removing/Installing Clutch Plate From Compressor
    GM2000947Courtesy of GENERAL MOTORS CORP.
  9. Install the clutch plate onto the A/C compressor.
    10. Fig 8: Removing/Installing Compressor Clutch Plate
    GM2000942Courtesy of GENERAL MOTORS CORP.
  10. Install the ORIGINAL clutch plate retaining nut and using the J 37872  . See Special Tools .

    Tighten:  Tighten the screws to 25 N.m (18 lb ft).

    11. Fig 9: Measuring Air Gap Between Clutch Plate & Clutch Pulley
    GM2000977Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Make certain that the clutch plate does not drag or interfere with the pulley when rotated.
  11. Measure the air gap between the clutch plate and the clutch pulley. The air gap should be 0.3-0.7 mm (0.012-0.028 in). If the air gap is not within specification, remove shaft nut and clutch plate and use an alternate shim included in the service kit to achieve the proper air gap.
  12. Remove the ORIGINAL clutch plate retaining nut and install the NEW nut provided in the kit.

    Tighten:  Tighten the screws to 25 N.m (18 lb ft).

  13. Remove the A/C compressor from the compressor stand or other suitable support fixture and remove the cap or tape from the A/C compressor ports.
  14. Install the A/C compressor to the vehicle. Refer to Air Conditioning Compressor Replacement (L61, LE5)  or Air Conditioning Compressor Replacement (LNF) .
  15. Leak test the fittings using the J 39400-A  . See Special Tools .
scientia non olet · About LEMON Manuals