Compressor Clutch Assembly Replacement L61

Tools Required

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



2. Remove the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
3. Remove the right radiator air deflector retainers.
4. Remove the right radiator air deflector.
5. Remove the engine drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 2.2L (L61).

Important: Discharge of the A/C system is not required.

6. Remove the compressor mounting bolts.
7. Remove the compressor from the engine with compressor line attached.




Important: Remove the 3 adjustable dowels from the J 37872 .

Install three 5/16 x 1 inch bolts in place of the dowels.
8. Remove and discard the compressor clutch plate bolt.

Use the J 37872 to hold the compressor clutch plate from turning.




9. Remove the compressor clutch plate from the compressor.



10. Remove the compressor pulley snap ring using the J 6083 .



11. Remove the compressor pulley from the compressor.



12. Remove the compressor clutch coil snap ring using the J 6083 .



13. 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 .



4. Install the compressor pulley to the compressor.



5. Install the compressor pulley snap ring using the J 6083 .
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.




Important: 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.




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

9. Install the clutch drive plate bolt.

Notice: Refer to Fastener Notice in the Preface section.

10. Tighten the compressor clutch drive plate bolt.

Use the J 37872 to hold the compressor clutch plate from turning.

Tighten
Tighten the bolt to 12 N·m (106 lb in).

11. Install the compressor to the engine.
12. Install the compressor mounting bolts.

Tighten
Tighten the bolt to 50 N·m (37 lb ft).

13. Install the engine drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 2.2L (L61).

Important: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.




14. Install the right radiator air deflector.
15. Install the right radiator air deflector retainers.
16. Install the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
17. Lower the vehicle.

Compressor Clutch Assembly Replacement LX9

Tools Required

1. Remove the engine drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.5L (LX9).
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



3. Remove the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
4. Remove the right radiator air deflector retainers.
5. Remove the right radiator air deflector.

Important: Discharge of the A/C system is not required.

6. Remove the compressor mounting bolts.
7. Remove the compressor from the engine with compressor line attached.




Important: Remove the 3 adjustable dowels from the J 37872 .

Install three 5/16 x 1 inch bolts in place of the dowels.
8. Remove and discard the compressor clutch plate bolt.

Use the J 37872 to hold the compressor clutch plate from turning.




9. Remove the compressor clutch plate from the compressor.



10. Remove the compressor pulley snap ring using the J 6083 .



11. Remove the compressor pulley from the compressor.



12. Remove the compressor clutch coil snap ring using the J 6083 .



13. 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 .



4. Install the compressor pulley to the compressor.



5. Install the compressor pulley snap ring using the J 6083 .
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.




Important: 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.




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

9. Install the clutch drive plate bolt.

Notice: Refer to Fastener Notice in the Preface section.

10. Tighten the compressor clutch drive plate bolt.

Use the J 37872 to hold the compressor clutch plate from turning.

Tighten
Tighten the bolt to 12 N·m (106 lb in).

11. Install the compressor to the engine.
12. Install the compressor mounting bolts.

Tighten
Tighten the bolt to 50 N·m (37 lb ft).

Important: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.




13. Install the right radiator air deflector.
14. Install the right radiator air deflector retainers.
15. Install the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
16. Lower the vehicle.
17. Install the engine drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.5L (LX9).