INSTALLATION
DENSO A/C COMPRESSOR
NOTE: Typical A/C compressor and clutch assembly shown in illustrations.
1. Align the dowel pin on the back of the compressor clutch field coil (2) with the hole in the front of the A/C compressor (3) and position the field coil onto the compressor. Be certain that the compressor clutch field coil wire lead is properly routed so that it is not pinched between the A/C compressor and the field coil.
CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor.
NOTE: A new snap ring must be used to secure the compressor clutch field coil to the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or to the left of the field coil dowel pin location on the A/C compressor.
2. Using Snap Ring Pliers 9764 or equivalent (1), install the snap ring (4) that secures the compressor clutch field coil to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented correctly.
CAUTION: Be certain to position the compressor clutch field coil wire lead so that it is not damaged during A/C compressor pulley and bearing installation.
CAUTION: When installing the pulley and bearing assembly, DO NOT mar the friction surfaces of the pulley or premature failure of the clutch will result.
3. Install the pulley and bearing assembly (1) onto the front of the A/C compressor. If necessary, tap the pulley gently with a block of wood (2) placed on the pulley friction surface.
CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor.
NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward.
4. Using Snap Ring Pliers 9764 or equivalent (1), install the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove.
5. If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original shim(s) (3) onto the compressor shaft (1). If a new clutch plate and pulley and bearing assembly are being used, install a trial stack of shims 2.54 mm (0.010 in.) thick onto the compressor shaft.
6. Install the clutch plate (4) onto the front of the A/C compressor (5).
7. Install the compressor shaft bolt (3). Tighten the bolt to 19 N·m (168 in. lbs.).
NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is correct. Spin the pulley before performing a final check of the air gap.
NOTE: On models with the clutch plate recessed into the pulley, use a 90° wire gap gauge to measure the clutch air gap. On other models, use a blade type feeler gauge to measure the air gap.
8. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly. The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024 in.). If the air gap is not between specifications, add or subtract shims as needed until the correct air gap is obtained.
CAUTION: Be certain that the compressor clutch field coil wire lead is routed so that it is not pinched between the A/C compressor and the field coil connector bracket.
9. Carefully route the compressor clutch field coil wire lead behind the connector bracket (2).
10. Install the compressor clutch field coil connector (1) onto the connector bracket and connect the engine wire harness to the field coil connector.
11. Install the front skid plate (refer to 13 - FRAME & BUMPERS/FRAME/FRONT SKID PLATE - INSTALLATION).
12. Lower the vehicle.
13. Install the accessory drive belt (refer to 7 - COOLING/ACCESSORY DRIVE/BELTS-DRIVE - INSTALLATION).
14. Reconnect the negative battery cable.
VISTEON A/C COMPRESSOR
1. Position the A/C clutch field coil (1) squarely onto the front of the A/C compressor (2).
CAUTION: Position the A/C clutch field coil so that the coil positioning tabs and the wire harness lead are oriented in the correct direction. Failure to correctly position the field coil on the A/C compressor will result in field coil damage.
2. Align the field coil positioning tabs to the recessed area at the front of the A/C compressor and install the clutch field coil onto the compressor using a two jaw puller (3), compressor field coil installer (Special Tool 9352 in Kit 9349) (4) and the compressor field coil installer spacer (Special Tool 9353 in Kit 9349) (5).
3. Position the clutch field coil wire lead and bracket (2) to the A/C compressor (3) and install the screw (1) that secures the bracket to the compressor. Tighten the screw to 4 N·m (35 in. lbs.).
4. Align the pulley and bearing assembly (1) squarely onto the front of the A/C compressor (2).
NOTE: A distinct change of sound during the clutch pulley tapping process indicates that the pulley and bearing assembly has bottomed out against the compressor housing.
5. Using clutch pulley installer (Special Tool 9355 in Kit 9349) (3) and a hammer (4), install the pulley and bearing assembly onto the front of the A/C compressor. Tap the installer with a hammer until the pulley and bearing assembly has bottomed against the compressor housing.
CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in clutch failure and severe damage to the A/C compressor.
NOTE: Install the snap ring with the beveled side of the snap ring facing outward.
6. Using snap ring pliers (Special Tool 9764 or equivalent) (1), install the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor (4). Make sure the snap ring is properly seated in the groove.
7. Verify that there is adequate clearance for the clutch field coil wire lead (1) between the housing of the A/C compressor (2) and the pulley and bearing assembly (3).
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 the 1.0, 0.50 and 0.13 millimeter (0.040, 0.020 and 0.005 inch) shims from the clutch hardware package which is provided with the new clutch.
8. Install the clutch shims onto the compressor shaft.
9. Using a strap wrench (4), install the bolt (5) that secures the clutch plate (6) to the A/C compressor. Hold the clutch plate stationary with the strap wrench and tighten the bolt to 15 N·m (133 in. lbs.).
10. Using 90° wire gauges (1), check the air gap between the clutch plate (2) and the pulley and bearing assembly (3). If the air gap is not between 0.35 to 0.65 millimeter (0.014 to 0.025 inch), add or subtract shims as required.
11. Position the A/C compressor onto the mounting bracket.
12. Install the bolts that secure the A/C compressor to the mounting bracket (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/COMPRESSOR-A/C - 3.7L ENGINE - INSTALLATION).
13. Connect the engine wire harness to the compressor clutch field coil connector.
14. Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
15. Reconnect the negative battery cable.
16. Perform the Clutch Break-in Procedure (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/A/C COMPRESSOR CLUTCH - STANDARD PROCEDURE).