I've now done 2 of these and have seen more than a few threads of people complaining about theirs. I've been meaning to do this for a while so I decided to put together this how-to now so you can do-it-yourself.
Tools required:
-10mm (8mm) sockets/box wrench.
-AC pulley puller ( I purchased one from Sears-Craftsman, but Autozone has them to rent)
-1/2 inch socket wrench or breaker bar
-Strap wrench
-Snap Ring Pliers
-Rubber Mallet
-Hammer
-Block of wood.
Instructions:
1. Disconnect the battery (every job begins with this tidbit... )
2. Disconnect the AC wiring harness from the clutch assembly.
If you don't have a strap wrench:
3. With the serpentine belt still in place (to minimize movement), loosen the center bolt(it's either 10mm or 8mm). You may need to jam the pulley with a screwdriver to keep it from turning. DO NOT REMOVE THE BOLT YET, LOOSEN ONLY.
4. Once the bolt is loosened, remove the belt with the 1/2 inch socket wrench or breaker bar inserted into the tensioner.
With a strap wrench:
5. Hold the pulley in place with the strap wrench while loosening the center bolt with a 10mm (8mm) socket.
6. Once the bolt is loosened, remove the belt. (Unless you have already done so when using the strap wrench)
7. Remove the bolt and slide the pulley cover off. There is a spacer inside of the cover. Hang on to it to reuse or compare it to the new spacers if your new clutch includes them and you will replace with one like.
8. With the snap ring pliers, remove the snap ring from the compressor shaft.
9. Take the AC pulley puller, attach it to the pulley per the instructions with the pulley. Slowly remove the pulley.
(NOTE: There is something directly in front of the pulley (don't remember what it is) so be careful not to bind the puller against it. You can loosen the part that is in the way and move it some.)
10. Take a large screwdriver and gently but with force remove the coil from the compressor housing. Loosen a small amount, then move to the opposite side, a little at a time.
11. Now take the new coil and slide it onto the compressor housing...making sure the coil electrical connector is lined up with the indention on the housing. Take the rubber mallet and seat the coil. It should slide right on but if you need more force get a 4x4 block of wood and a hammer to tap it into place. The coil HAS to seat perfectly onto the housing or the pulley will not slide on. Examine the the area where the coil seats from top to bottom. Make sure it is completely flush with the housing. No gap between the coil and compressor housing.
12. Take the pulley and slide it onto the shaft. It should go right on without much force. If it will not, check the coil to make sure it is properly seated. You can take the hammer and tap into place.
13. Replace the snap ring.
14. Use a feeler gauge to measure the spacers for the air gap (generally between .018 and .030) or match the old spacer with the new and drop it into the new pulley cover. Make sure it lays flat inside the shaft so that the bolt will slide through.
14. Slide the cover unto the shaft and replace the bolt. Use the strap wrench to hold the pulley while tightening.
15. Replace the serpentine belt.
16. Reconnect the AC coil harness and the battery.
17. Crank the car. Make sure the AC is off and check the compressor. The pulley should turn but the compressor should be off. Now turn on the AC and compressor should run. If not or if it is hesitating you may need to try another spacer. Rule of thumb is 1/8 (.015-.025) of an inch is needed between the coil and the pulley cover for the compressor to operate but if you match the spacer with the old it should be OK.
NOTE:
This was done from memory and I should have taken pics when I did these but this will give you a general of how to replace it. If anyone has any input feel free to include it.
Tools required:
-10mm (8mm) sockets/box wrench.
-AC pulley puller ( I purchased one from Sears-Craftsman, but Autozone has them to rent)
-1/2 inch socket wrench or breaker bar
-Strap wrench
-Snap Ring Pliers
-Rubber Mallet
-Hammer
-Block of wood.
Instructions:
1. Disconnect the battery (every job begins with this tidbit... )
2. Disconnect the AC wiring harness from the clutch assembly.
If you don't have a strap wrench:
3. With the serpentine belt still in place (to minimize movement), loosen the center bolt(it's either 10mm or 8mm). You may need to jam the pulley with a screwdriver to keep it from turning. DO NOT REMOVE THE BOLT YET, LOOSEN ONLY.
4. Once the bolt is loosened, remove the belt with the 1/2 inch socket wrench or breaker bar inserted into the tensioner.
With a strap wrench:
5. Hold the pulley in place with the strap wrench while loosening the center bolt with a 10mm (8mm) socket.
6. Once the bolt is loosened, remove the belt. (Unless you have already done so when using the strap wrench)
7. Remove the bolt and slide the pulley cover off. There is a spacer inside of the cover. Hang on to it to reuse or compare it to the new spacers if your new clutch includes them and you will replace with one like.
8. With the snap ring pliers, remove the snap ring from the compressor shaft.
9. Take the AC pulley puller, attach it to the pulley per the instructions with the pulley. Slowly remove the pulley.
(NOTE: There is something directly in front of the pulley (don't remember what it is) so be careful not to bind the puller against it. You can loosen the part that is in the way and move it some.)
10. Take a large screwdriver and gently but with force remove the coil from the compressor housing. Loosen a small amount, then move to the opposite side, a little at a time.
11. Now take the new coil and slide it onto the compressor housing...making sure the coil electrical connector is lined up with the indention on the housing. Take the rubber mallet and seat the coil. It should slide right on but if you need more force get a 4x4 block of wood and a hammer to tap it into place. The coil HAS to seat perfectly onto the housing or the pulley will not slide on. Examine the the area where the coil seats from top to bottom. Make sure it is completely flush with the housing. No gap between the coil and compressor housing.
12. Take the pulley and slide it onto the shaft. It should go right on without much force. If it will not, check the coil to make sure it is properly seated. You can take the hammer and tap into place.
13. Replace the snap ring.
14. Use a feeler gauge to measure the spacers for the air gap (generally between .018 and .030) or match the old spacer with the new and drop it into the new pulley cover. Make sure it lays flat inside the shaft so that the bolt will slide through.
14. Slide the cover unto the shaft and replace the bolt. Use the strap wrench to hold the pulley while tightening.
15. Replace the serpentine belt.
16. Reconnect the AC coil harness and the battery.
17. Crank the car. Make sure the AC is off and check the compressor. The pulley should turn but the compressor should be off. Now turn on the AC and compressor should run. If not or if it is hesitating you may need to try another spacer. Rule of thumb is 1/8 (.015-.025) of an inch is needed between the coil and the pulley cover for the compressor to operate but if you match the spacer with the old it should be OK.
NOTE:
This was done from memory and I should have taken pics when I did these but this will give you a general of how to replace it. If anyone has any input feel free to include it.