GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 SL1/SC1 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Air Conditioning Clutch Coil Replacement

Tools Required
    • SA9149AC-2 Puller Center
    • SA9149AC-3 Drive Plate and Pulley Installer

Removal Procedure

    Object Number: 861528 Size: SH

    Important: It is not necessary to discharge the A/C system to service the A/C compressor clutch.

  1. Remove the accessory drive belt from the compressor clutch pulley by rotating the belt tensioner clockwise using a 14 mm (9/16 in) wrench. Snap-On™ tool S8190A or equivalent can be used.
  2. Disconnect the A/C compressor clutch electrical connector.

    3. Important: The next 7 steps are only necessary if the vehicle is equipped with a secondary air pump reaction system (AIR).

  3. Remove the nuts from the combination valve studs.
  4. Remove the air hose.
  5. Remove the vacuum source hose. There is no need to disconnect the internal vacuum hose for this procedure.
  6. Remove the combination valve and gasket from the rear air compressor bracket.
  7. Position the combination valve and gasket away from the A/C compressor bracket.

    8. Object Number: 865483 Size: SH
  8. Remove the air pipe nuts from the exhaust manifold studs.
  9. Remove the air pipe.

    10. Object Number: 861409 Size: SH
  10. Remove the rear A/C compressor-to-engine bracket bolts.
  11. Remove the front A/C compressor-to-engine bracket bolts.

    12. Notice: Ensure that A/C discharge line does not change position and/or loosen at the condenser connection due to moving discharge line. Failure to ensure a tight connection will result in a system refrigerant leak.


    Object Number: 861526 Size: SH
  12. With the A/C lines still attached, lift the A/C compressor upward and install one front bolt through the front engine bracket top hole and bottom rear mounting ear of the A/C compressor. Tighten the bolt so that the A/C compressor is supported by the bracket.

    13. Object Number: 861524 Size: SH
  13. Position the screwdriver between 2 vibration dampeners on the front of the clutch face and remove the clutch bolt.

    14. Object Number: 861953 Size: SH

    Important: Be careful not to lose shims inside of the clutch drive plate opening when removing the drive plate from the compressor shaft.

  14. Position the flat blade screwdriver under the clutch drive plate and pry out evenly to remove.

    15. Object Number: 861522 Size: SH
  15. Using external snap ring pliers, remove the snap ring.

    16. Notice: Do not remove pulley without puller adapter. If A/C compressor shaft is pressed on, A/C compressor will be damaged.


    Object Number: 861521 Size: SH
  16. Position the tool SA9149AC-2 on the end of the A/C compressor shaft.

    17. Important: Make sure to hook the puller jaw behind the pulley.

  17. Install the 3-jaw puller on the A/C compressor pulley. Tighten the center bolt to remove the pulley assembly.

    18. Important: To enable easier removal of the screws, lightly tap on the end of the screwdriver with a plastic hammer.

  18. Remove the 3 A/C compressor clutch coil screws and remove the A/C compressor clutch coil.

Installation Procedure

    Object Number: 861518 Size: SH
  1. Position the A/C compressor clutch coil so that the electrical connector is aligned with the indent in the compressor front head.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the three A/C compressor clutch coil screws.

    3. Tighten
    Tighten the clutch coil-to-compressor screws to 5 N·m (44 lb in).


    Object Number: 861515 Size: SH
  3. Place the SA9149AC-3 on the installation bolt and insert it through the center of the pulley. Thread the installation bolt into the end of the A/C compressor shaft and finger tighten.

    4. Object Number: 861509 Size: SH
  4. Finger tighten the nut on the installation bolt to align the pulley to the A/C compressor. While holding the end of the bolt, tighten the nut until the pulley bottoms out on the A/C compressor.
  5. Loosen the nut and remove the pulley installation bolt.

    6. Object Number: 861522 Size: SH
  6. Install the snap ring with the tapered side out using the snap ring pliers.

    7. Object Number: 861966 Size: SH
  7. Install the shims from the old drive plate opening to the new drive plate opening.

    8. Object Number: 861524 Size: SH
  8. Position the clutch drive plate on the compressor shaft making sure the splines line up. Press the shaft into place.
  9. Position the screwdriver between the two vibration dampners on the front of the clutch face and install the clutch bolt.

    10. Important: After tightening the center bolt, check to make sure that the pulley rotates smoothly by spinning it.

  10. Install the center bolt and tighten.

    11. Tighten
    Tighten the compressor clutch drive plate-to-compressor center bolt to 13 N·m (9 lb ft).


    Object Number: 873191 Size: SH
  11. Check to make sure the clutch clearance is 0.3-0.6 mm (0.012-0.024 in).
  12. If necessary, adjust the clearance by adding or removing shims provided. Refer to clutch drive plate removal steps in the removal procedure to add or remove shims.

    13. Object Number: 861409 Size: SH
  13. Remove the front bracket-to-compressor bolt and position the A/C compressor between the brackets.
  14. Install the A/C compressor to the front bracket with 3 bolts. Finger tighten the bolts.
  15. Install the A/C compressor to the rear bracket with 3 bolts. Tighten the front and rear bolts.

    16. Tighten

        • Tighten the A/C compressor front bolts-to-bracket to 49 N·m (36 lb ft).
        • Tighten the A/C compressor rear bolts-to-bracket to 25 N·m (19 lb ft).

    Notice: Make sure gaskets are installed correctly or a leak will occur. If gaskets are removed from stubs, replace with new gaskets. Installation steps must be performed in sequence.


    Object Number: 865483 Size: SH

    Important: The next 7 steps are only necessary if the vehicle is equipped with a secondary air pump reaction system (AIR).

  16. Install the air pipe onto the exhaust manifold studs.
  17. Install the air pipe into the rear air compressor bracket slot.
  18. Install the combination valve studs into the rear air compressor bracket through the air pipe flange holes.
  19. Install and tighten the nuts on the combination valve studs.

    20. Tighten
    Tighten the air system combination valve nuts to 7 N·m (62 lb in).

  20. Install and tighten the nuts on the exhaust manifold studs.

    21. Tighten
    Tighten the air system pipe-to-exhaust manifold studs to 7 N·m (62 lb in).


    Object Number: 865502 Size: SH
  21. Install the vacuum source hose.
  22. Install the air hose.

    23. Object Number: 861528 Size: SH
  23. Connect A/C the compressor clutch electrical connector.
  24. Install the accessory drive belt.
  25. Start the engine and engage the A/C compressor 10-15 cycles to break-in new A/C compressor clutch. This cycling of the A/C compressor will match the drive plate and the pulley surfaces.