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Clutch Assembly: Installation

  1. Clean clutch coil and pulley mating surfaces. Install clutch coil. Ensure clutch coil is properly aligned on compressor head. Install snap ring with beveled side facing outward. Install pulley assembly onto compressor. If properly aligned, pulley assembly should slip onto compressor. If necessary, use Pulley Replacer (T97P-19D786-A) and gently tap pulley into place. Install snap ring with beveled side facing outward.
  2. Install shim. Align clutch plate with block tooth on compressor shaft and install clutch plate. Install thermal cut-out switch and tighten switch bracket bolt to 53 INCH lbs. (6 N.m). Using spanner wrench, install shaft nut and tighten to 13 ft. lbs. (17 N.m).
  3. Using a feeler gauge, measure air gap between clutch plate and pulley assembly at 3 equally spaced locations. Rotate pulley 180 degrees, and measure air gap at 3 locations again. On 2000 LS, air gap should be 0.014-0.033" (0.35-0.85 mm). On 2001 LS, air gap should be 0.014-0.030" (0.35-0.75 mm). On all models, if air gap is not within specification, add or remove shims to obtain correct air gap.
  4. Add correct amount of refrigerant oil to compressor and install compressor. See COMPRESSOR REFRIGERANT OIL CHECKING. Evacuate and charge A/C system. Perform leak test.
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