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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Heating, Ventilation And Air Conditioning >> Repair Instructions >> Compressor Clutch Coil Replacement >> Installation Procedure

Installation Procedure

  1. Install the clutch coil to the compressor.
  2. Place the clutch coil assembly on the front head. Position the terminals (1) at the marked location.
    Fig 1: Identifying Clutch Coil Assembly Terminals
    G01645540Courtesy of GENERAL MOTORS CORP.
  3. Place the J 33024  over the internal opening of the clutch coil housing (1).
  4. Align the J 33024  with the compressor front head.
  5. Center the J 8433-1  in the counter-sunk center hole of the J 33024. 
  6. Install the two bolts and washers through the crossbar slots.
  7. Thread the bolts into the J 34992  in order to achieve full fixture thickness.
  8. Turn the center forcing screw of the J 8433-1  in order to force the clutch coil onto the front head. Ensure that the clutch coil and the J 33024  remain aligned during installation.
    Fig 2: Installing Clutch Coil Into Front Head
    G01645541Courtesy of GENERAL MOTORS CORP.
  9. When the coil is fully seated on the front head, mark the front head at 3 places 120 degrees apart.
    Fig 3: Identifying Staking Locations On Front Head
    G01645542Courtesy of GENERAL MOTORS CORP.

    Important:  Ensure that the stake size is only one-half the area of the punch tip. Ensure that the stake is only approximately 0.28-0.35 mm (0.010-0.015 in) deep.

  10. Use a 1/8 inch diameter drift punch (2) in order to stake the front head at 3 places 120 degrees apart (3), in order to ensure that the clutch coil (1) remains in position.
    Fig 4: Staking Front Head
    G01645543Courtesy of GENERAL MOTORS CORP.
  11. With the compressor mounted to the J 34992,  position the pulley rotor (1) and bearing assembly on the front head.
    Fig 5: Aligning Pulley Rotor & Bearing Assembly On Front Head
    G01645544Courtesy of GENERAL MOTORS CORP.
  12. Position the J 33017  and the J 33023-A  directly over the inner race of the bearing.
  13. Position the J 8433-1  on the J 33023-A. 
  14. Assemble the two bolts and washers through the puller bar slots.
  15. Thread the bolts into the J 34992.  Ensure that the thread of the through bolts engages the full thickness of the J 34992. 
  16. Tighten the center screw in the J 8433-1  in order to force the pulley rotor and bearing assembly onto the compressor front head.
  17. If the J 33017  slips off direct in-line contact with the inner race and bearing, perform the following steps:
    1. 17.1. Loosen the J 8433-3. 
    2. 17.2. Realign the installer and the pilot in order to ensure that the J 33017  properly clears the front head.
  18. Use the J 6083  in order to install the following components:
    • The pulley rotor (1)
    • The retainer ring (2)
      • Fig 6: Installing Pulley Rotor & Retainer Ring
      G01645545Courtesy of GENERAL MOTORS CORP.
  19. Install the clutch plate and hub assembly. Refer to COMPRESSOR CLUTCH PLATE/HUB ASSEMBLY REPLACEMENT .
  20. Install the compressor to the vehicle. Refer to COMPRESSOR REPLACEMENT .
  21. Evacuate and recharge the refrigerant system. Refer to REFRIGERANT RECOVERY AND RECHARGING .
  22. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A. 
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