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Clutch-A/C Compressor: Installation

WARNING: This page is about a different car, the 2005 Jeep Grand Cherokee. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Locating Clutch Field Coil Snap Ring
GC0001398Courtesy of DAIMLERCHRYSLER CORP.
  1. Align the dowel pin on the back of the clutch field coil (2) with the hole in the compressor front cover (3) and position the clutch field coil onto the A/C compressor. Be certain that the clutch coil wire harness is properly oriented and routed so that it is not pinched between the compressor front cover and the clutch field coil.
    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 clutch field coil to the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or to the left of the clutch field coil dowel pin location on the A/C compressor.
  2. Using snap ring pliers (Special Tool C-4574 or equivalent) (1), install the external snap ring (4) that secures the clutch field coil to the front cover of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented correctly.
  3. Install the screw that secures the clutch field coil wire harness connector bracket and ground clip to the top of the compressor housing. Tighten the screw securely.
    Fig 2: Installing Pulley & Bearing Assembly
    GC0001402Courtesy of DAIMLERCHRYSLER CORP.
    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.
  4. Install the pulley and bearing assembly (1) onto the front cover of the A/C compressor. If necessary, tap the pulley gently with a block of wood (2) placed on the pulley friction surface.
    Fig 3: External Snap Ring
    GC0001399Courtesy of DAIMLERCHRYSLER CORP.
    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.
  5. Using snap ring pliers (Special Tool C-4574 or equivalent) (2), install the external snap ring (1) that secures the pulley and bearing assembly (3) to the front cover of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove.
    Fig 4: Clutch Plate and Shim(s)
    GC0001400Courtesy of DAIMLERCHRYSLER CORP.
  6. If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original shim(s) (3) on the compressor shaft (1) against the shoulder. If a new clutch plate and/or pulley and bearing assembly are being used, install a trial stack of shims 2.54 mm (0.010 in.) thick on the compressor shaft against the shoulder.
    Fig 5: A/C Compressor Shaft Bolt
    GC0001401Courtesy of DAIMLERCHRYSLER CORP.
  7. Install the clutch plate (2) onto the compressor shaft.
  8. Install the compressor shaft bolt (1). Tighten the bolt to 19 N.m (168 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.
  9. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly faces with a feeler gauge. The air gap should be between specifications (Refer to HEATING & AIR CONDITIONING - SPECIFICATIONS) . If the proper air gap is not obtained, add or subtract shims as needed until the desired air gap is obtained.
  10. Install the bolts that secure the A/C compressor to the engine (Refer to HEATING & AIR CONDITIONING/PLUMBING/COMPRESSOR-A/C - INSTALLATION) .
  11. Connect the engine wire harness connector to the A/C compressor clutch coil.
  12. Install the accessory drive belt (Refer to COOLING/ACCESSORY DRIVE/BELTS-DRIVE - INSTALLATION) .
  13. Reconnect the negative battery cable.
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