Special Tools

1. Remove the accessory drive belt from the A/C compressor. Refer to Drive Belt Replacement for the 3.8L (L26) engine or Drive Belt Replacement - Accessory for the 5.3L (LS4) engine.
2. Remove the compressor. Refer to Air Conditioning Compressor Replacement.
3. Remove the lower air deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement.




Note: Remove the 3 adjustable dowels from J 37872 Compressor Clutch Holding Tool .

Install three 5/16x1 inch bolts in place of the dowels.
4. Remove and discard the compressor clutch plate bolt.

Use the J 37872 Compressor Clutch Holding Tool to hold the compressor clutch plate from turning.




5. Remove the compressor clutch plate from the compressor.



6. Remove the compressor pulley snap ring using the J 6083 Snap Ring Pliers .



7. Remove the compressor pulley from the compressor.



8. Remove the compressor clutch coil snap ring using the J 6083 Snap Ring Pliers .



9. Remove the compressor clutch coil from the compressor.

1. Carefully clean the clutch plate bolt threads with a M6x1.0 tap. Carefully blow out debris with compressed air.



2. Install the compressor clutch coil to the compressor.



3. Install the compressor clutch coil snap ring using the J 6083 Snap Ring Pliers .



4. Install the compressor pulley to the compressor.



5. Install the compressor pulley snap ring using the J 6083 Snap Ring Pliers .
6. Place a small amount of oil on the 0.4 mm (0.016 in) air gap shim and place inside the clutch drive plate.



7. Install the compressor clutch plate to the compressor.




Note: Make certain that the drive plate does not drag against the pulley when the pulley is rotated.

8. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.3-0.6 mm (0.012-0.024 in) air gap.




Note: Make certain that the new drive plate bolt has colored adhesive on at least 5 threads.

9. Install the clutch drive plate bolt.

Caution: Refer to Fastener Caution in the Preface section.

10. Tighten the compressor clutch drive plate bolt to 12 N·m (106 lb in).

Use the J 37872 Compressor Clutch Holding Tool to hold the compressor clutch plate from turning.

11. Install the compressor. Refer to Air Conditioning Compressor Replacement
12. Install the accessory drive belt to the A/C compressor. Refer to Drive Belt Replacement for the 3.8L (L26) engine or Drive Belt Replacement - Accessory for the 5.3L (LS4) engine.
13. Install the lower air deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement.
14. Leak test the fittings using the J 39400-A Halogen Leak Detector .