ac compressor clutch/coil removal DIY
Here we go, as I promised, - enjoy!
take a note of the belt routing before starting this procedure
1. use 15mm open end wrench or anything similar to pull serpentine belt tensioner towards the front of car, this will release the tension of the belt and have a nail ready so that you can push the nail through the both openings and lock tensioner in released position.
2. remove 3 x 13mm tensioner bolts to to take out belt tensioner (very easy)
3. remove 2 x 13mm alternator mount bolts, remove the plastic cap that is protecting main alternator to battery (thick black) wire to be able to see 1 x 13mm nut, remove that nut.
4. now you can use pry-bar to separate alternator away from the engine
5. in picture #1 you can see two long bolts that hold AC compressor, you can use 16mm deep socket with 3/8 drive from the top to loosen top bolt and the same for the bottom bolt but from the bottom side. (you don't even have to remove the plastic side splash shield and the plastic cooler hose).
6. you can now remove 2 x 16mm ac compressor bolts (yes you will have enough room).
7. even with bolts removed ac compressor will be in its place stuck so you will have to use pry-bar again to separate it from the engine. This time have something handy like wire or something that you can tie the compressor in the clutch up position like I did on picture #2 WARNING DO NOT DISCONNECT ANY AC LINES, ALSO BE CAREFUL WHEN YOU PULL THE COMPRESSOR UP SO THAT YOU DON'T BREAK THE PLASTIC COOLANT HOSE PIPE NEAR THE ENGINE BLOCK OR DAMAGE COOLANT HOSE.
8. now everything is easy, spray some pb blaster or wd40 on the center bolt and remove the center 15mm bolt while using chenel locks to hold the 3 little circles from the clutch like I did on picture 3
9. bolt was easy to remove, and now you can simply lift the clutch up and remove it like I did on picture 4 (be careful not to loose thin shim that will be stuck to the other side of the clutch
10. once the clutch is removed you will be able to see the pulley side of the clutch mechanism, you will also see snap-ring inside see picture #6 (this one was easy)
11. as I said this snap ring was easy to remove, now you will have to use pry-bar or bigger flat head please see my note on picture #4 where arrow show you will use one of the bolts as a leverage point to pry under the pulley and lift up (surprisingly pulley lifted up without any problems).
12. once pulley is out, you will see the clutch coil, (you will see it as on the last picture of the part one - but this was my new coil installed)
13. WARNING in order to remove the coil you will have to fight for some time with this bigger snap ring, my pliers did not open wide enough so I finally decided to use the help of smaller flat head screwdriver ( I knew it was dangerous, I had protective glasses and this spring literally jumped into my forehead and bounced of in the direction of the coolant reservoir. So be careful please!
14. once you remove your coil, you will see same as I did on picture #11 of the first part.
15. save your old connector from the old coil since new coils will not come with connector, see pictures 7 and 8.
16. on picture #9 you will see small arrow showing this little guide pin on the clutch coil, you will have to put this guide pin into the little dent shown with an arrow on picture #11
17. make sure that during your installation of the dangerous snap ring the coil does not jump out of its locking place.
18. again shorter fight with installation of the snap ring (since mine was bending and wasn't going on straight I had to use smaller screwdriver to keep pressure on the opposite end of the ring to so it does not slide up as I push the other end down.
19. install pulley and its snap ring
20. see picture #4 of the second par, note that there are splines and flat spot on the shaft, the same is on the clutch (see picture #3 and #4 of the second part) so make sure they click in with each other. (don't forget the shim under the clutch)
21. again repeat the same step from picture #3 of the first part to tighten the center bolt and you are done.
22. install compressor back to its place (put some grease on the mounting area so that the compressor slides in easier
23. install alternator (this would be good opportunity to check alt. pulley vs alt fan operation)
24 install serpentine belt tensioner
25. don't forget belt
Also if you have problems with cooling fans and suspect that your fan control module FCM is bad, do not order another one before you check my pdf fille on the bottom of part 2.
Here we go, as I promised, - enjoy!
take a note of the belt routing before starting this procedure
1. use 15mm open end wrench or anything similar to pull serpentine belt tensioner towards the front of car, this will release the tension of the belt and have a nail ready so that you can push the nail through the both openings and lock tensioner in released position.
2. remove 3 x 13mm tensioner bolts to to take out belt tensioner (very easy)
3. remove 2 x 13mm alternator mount bolts, remove the plastic cap that is protecting main alternator to battery (thick black) wire to be able to see 1 x 13mm nut, remove that nut.
4. now you can use pry-bar to separate alternator away from the engine
5. in picture #1 you can see two long bolts that hold AC compressor, you can use 16mm deep socket with 3/8 drive from the top to loosen top bolt and the same for the bottom bolt but from the bottom side. (you don't even have to remove the plastic side splash shield and the plastic cooler hose).
6. you can now remove 2 x 16mm ac compressor bolts (yes you will have enough room).
7. even with bolts removed ac compressor will be in its place stuck so you will have to use pry-bar again to separate it from the engine. This time have something handy like wire or something that you can tie the compressor in the clutch up position like I did on picture #2 WARNING DO NOT DISCONNECT ANY AC LINES, ALSO BE CAREFUL WHEN YOU PULL THE COMPRESSOR UP SO THAT YOU DON'T BREAK THE PLASTIC COOLANT HOSE PIPE NEAR THE ENGINE BLOCK OR DAMAGE COOLANT HOSE.
8. now everything is easy, spray some pb blaster or wd40 on the center bolt and remove the center 15mm bolt while using chenel locks to hold the 3 little circles from the clutch like I did on picture 3
9. bolt was easy to remove, and now you can simply lift the clutch up and remove it like I did on picture 4 (be careful not to loose thin shim that will be stuck to the other side of the clutch
10. once the clutch is removed you will be able to see the pulley side of the clutch mechanism, you will also see snap-ring inside see picture #6 (this one was easy)
11. as I said this snap ring was easy to remove, now you will have to use pry-bar or bigger flat head please see my note on picture #4 where arrow show you will use one of the bolts as a leverage point to pry under the pulley and lift up (surprisingly pulley lifted up without any problems).
12. once pulley is out, you will see the clutch coil, (you will see it as on the last picture of the part one - but this was my new coil installed)
13. WARNING in order to remove the coil you will have to fight for some time with this bigger snap ring, my pliers did not open wide enough so I finally decided to use the help of smaller flat head screwdriver ( I knew it was dangerous, I had protective glasses and this spring literally jumped into my forehead and bounced of in the direction of the coolant reservoir. So be careful please!
14. once you remove your coil, you will see same as I did on picture #11 of the first part.
15. save your old connector from the old coil since new coils will not come with connector, see pictures 7 and 8.
16. on picture #9 you will see small arrow showing this little guide pin on the clutch coil, you will have to put this guide pin into the little dent shown with an arrow on picture #11
17. make sure that during your installation of the dangerous snap ring the coil does not jump out of its locking place.
18. again shorter fight with installation of the snap ring (since mine was bending and wasn't going on straight I had to use smaller screwdriver to keep pressure on the opposite end of the ring to so it does not slide up as I push the other end down.
19. install pulley and its snap ring
20. see picture #4 of the second par, note that there are splines and flat spot on the shaft, the same is on the clutch (see picture #3 and #4 of the second part) so make sure they click in with each other. (don't forget the shim under the clutch)
21. again repeat the same step from picture #3 of the first part to tighten the center bolt and you are done.
22. install compressor back to its place (put some grease on the mounting area so that the compressor slides in easier
23. install alternator (this would be good opportunity to check alt. pulley vs alt fan operation)
24 install serpentine belt tensioner
25. don't forget belt
Also if you have problems with cooling fans and suspect that your fan control module FCM is bad, do not order another one before you check my pdf fille on the bottom of part 2.
