CLUTCH - FIXED DISPLACEMENT A/C COMPRESSOR

WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions may result in possible serious or fatal injury.

NOTE: The compressor clutch assembly can be serviced with the refrigerant system fully-charged and with the A/C compressor installed on the engine.

NOTE: Typical A/C compressor and clutch assembly shown in illustrations.

Fig. 206: A/C Compressor Shaft Bolt

1. Disconnect and isolate the negative battery cable.

2. Raise and support the vehicle.

3. Remove the splash shield from the right side frame rail.

4. Remove the accessory drive belt.

5. Disconnect the engine wire harness from the compressor clutch field coil connector (1) located on the top of the A/C compressor (5).

NOTE: Some models (depending on engine application) may require the A/C compressor to be removed from its installed location and repositioned to gain access to the compressor shaft bolt and/or pulley and field coil snap rings. However, the refrigerant system can still remain fully charged.

6. If necessary, remove the bolts that secure the A/C compressor to the engine and reposition the compressor to gain access to the shaft bolt and/or pulley and field coil snap rings.

7. Carefully remove the compressor clutch field coil connector and wire lead from the connector bracket (2).

8. Remove the compressor shaft bolt (3). A band-type oil filter wrench or a strap wrench may be used to hold the clutch plate (4) from rotating during bolt removal.

Fig. 207: Clutch Plate & Shim(s)

CAUTION: Do not pry between the clutch plate and the pulley and bearing assembly to remove the clutch plate from the compressor shaft as this may damage the clutch plate.

NOTE: Use care not to lose any clutch shim(s) during removal of the clutch plate, as they may be reused during the clutch plate installation process.

9. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft (1) and remove the clutch plate and shim(s) (3).

Fig. 208: Clutch Pulley & Snap Ring

10. Using A/C Snap Ring Pliers 9764 or equivalent (1), remove the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor and remove the pulley and bearing assembly.

Fig. 209: Clutch Coil & Snap Ring

11. Using A/C Snap Ring Pliers 9764 or equivalent (1), remove the snap ring (4) that secures the compressor clutch field coil (2) to the front of the A/C compressor (3) and remove the field coil.

A/C COMPRESSOR

WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow these instructions may result in possible serious or fatal injury.

NOTE: Variable displacement compressor shown in illustrations. Fixed displacement similar.

Fig. 210: A/C Compressor-Refrigerant Lines

1. Disconnect and isolate the negative battery cable.

2. Recover the refrigerant from the refrigerant system.

3. Raise and support the vehicle.

4. Remove the splash shield from the right side frame rail.

5. Remove the accessory drive belt.

6. Disconnect the engine wire harness (1) from the clutch coil or compressor control valve (2), depending on application.

7. Remove the nuts (4) that secure the A/C discharge line (5) and the A/C suction line (6) to the A/C compressor (3).

8. Disconnect the A/C discharge and suction lines from the A/C compressor and remove and discard the O-ring seals and gaskets.

Fig. 211: A/C Compressor-Removal/Installation

9. Support the A/C compressor (1) and remove the three bolts (2) that secure the compressor to the engine and remove the compressor.

10. Install plugs in, or tape over the opened refrigerant line fittings and compressor ports.