A/C Compressor Clutch: Installation

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.

Position the A/C clutch field coil onto the A/C compressor front housing.
Install the snap ring that secures the clutch field coil to the compressor front housing with snap ring pliers.
NOTE: Care must be taken not to pinch the wire harness with the retaining clip when tightening the retaining screw.
Install the screw that secures the clutch coil wire harness retainer clip to the compressor front housing. Tighten the screw securely.
Align the pulley and bearing assembly squarely onto the compressor front housing hub.
Install the pulley and bearing assembly onto the compressor front housing hub with installer (Special Tool 6871). See Fig 1. Thread the installer onto the compressor shaft, then turn the installer nut until the pulley and bearing assembly is seated against the compressor front housing.

Fig 1: A/C Clutch Pulley Installer
Courtesy of DAIMLERCHRYSLER CORP.

1 - PULLEY AND BEARING ASSEMBLY

2 - INSTALLER

CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in a clutch failure and severe damage to the front housing of the compressor.

NOTE: Install the snap ring with the beveled side of the snap ring facing outward.
Install the snap ring that secures the pulley and bearing assembly to the compressor. Press the snap ring to make sure it is properly seated in the groove.
Verify that there is adequate clearance between the clutch field coil wire and the clutch pulley.
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 1.0, 0.50, and 0.13 millimeter (0.040, 0.020, and 0.005 inch) shims from the clutch hardware package that is provided with the new clutch.
Install the clutch shims onto the compressor shaft.
NOTE: A distinct change of sound during the clutch plate tapping process indicates that the clutch plate has bottomed out against the compressor clutch shims.
Install the clutch plate using driver (Special Tool 6463 in Kit 6460). See Fig 2. Tap the clutch plate over the compressor shaft until it has bottomed against the clutch shims.

Fig 2: A/C Clutch Plate and Driver
Courtesy of DAIMLERCHRYSLER CORP.

1 - CLUTCH PLATE

2 - DRIVER
Install the clutch nut or bolt (depending on application) onto the compressor shaft. Tighten the nut to 17.5 N.m (155 in. lbs.).
NOTE: If the clutch air gap is not consistent around the circumference of the clutch, lightly pry up at the minimum variations and lightly tap down at the points of maximum variation.
Check the clutch air gap with a feeler gauge. See Fig 3. If the air gap does not meet the specification, add or subtract shims as required (Refer to HEATING & AIR CONDITIONING - SPECIFICATIONS.)

Fig 3: A/C Clutch Air Gap
Courtesy of DAIMLERCHRYSLER CORP.

1 - FEELER GAUGE
Position the A/C compressor onto the mounting bracket.
On the 2.4L gasoline and 2.5L/2.8L diesel engines, install and tighten the mounting bolts to 27 N.m (20 ft. lbs.).
On the 3.7L gasoline engine install all mounting bolts hand tight, then tighten the mounting bolts in the following sequence:
- The rear bolt to 55 N.m (41 ft. lbs.)
- The front inboard bolt to 40 N.m ( 30 ft. lbs.)
- The front outboard bolt to 55 N.m ( 41 ft. lbs.)
Connect the wire harness to the compressor clutch field coil connector.
Install the accessory drive belt (Refer to COOLING ).
Reconnect the negative battery cable.
Perform the Clutch Break-in Procedure (Refer to HEATING & AIR CONDITIONING/CONTROLS/A/C COMPRESSOR CLUTCH - STANDARD PROCEDURE) .