How to Replace a Compressor and Clutch

Do-it-yourself auto repair can seem a bit complicated. Unfamiliar terminology, tools, and a general uneasiness around all things motorized can be overwhelming. However, taking small steps, in conjunction with following manufacturer's guidelines, is a great beginning to becoming mechanically self-sufficient. A nice place to start is replacing the compressor and clutch for a non-working A/C. Read on to learn more.

Things You'll Need

• Recovery A/C unit
• Snap ring pliers
• 2-jaw puller
• Clutch assembly puller/installation tool (make/model specific)

Instructions

Compressor Removal

1. Recover the refrigerant with the A/C recovery unit.

2. Remove the drive belt from the A/C compressor. Some older compressors may have two belts, but most newer ones are fitted with a serpentine belt.

3. Unplug the field coil electrical connector.

4. Remove the manifold assembly from the A/C compressor.

5. Remove the bolts and studs holding the A/C compressor. The compressor should now be removed.

Clutch Assembly Removal

1. Remove the A/C clutch retaining nut.

2. Use the A/C clutch tool to remove the clutch plate.

3. Remove the clutch spacer.

4. Remove the A/C clutch pulley snap ring with the snap ring pliers.

5. Note the positioning of the coil connector for reassembly.

6. Remove the snap ring holding the field coil assembly.

7. Remove the field coil with the 2-jaw pullers.

Reassembly

1. Clean all parts.

2. Replace the clutch and field coil assembly with new ones.

3. Align the index pins on the A/C clutch field coil. Reverse the take off procedure to reinstall.

4. Measure and adjust A/C clutch air gap by adding or removing A/C clutch spacers. The gap width specifications should be included with the new clutch assembly.

5. Reverse the removal procedure for the compressor, as the clutch assembly and the A/C compressor should now be ready to reinstall.

6. Be sure to use new O-rings on the manifold along with a light PAG oil on the O-rings.

7. Pull a vacuum on the system. This removes moisture and air from the line.

8. Add a clean, factory recommended PAG oil, as well as a factory recommended refrigerant.

9. Check for line or seal leaks with a leak detector or soapy water.

Tips & Warnings

• Do not use air tools when working on a compressor and clutch assembly. Most of the parts are made of aluminum and could be damaged or destroyed if over tightened.