Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
1990 Geo Tracker L4-1590cc 1.6LFACTORY OEM SERVICE PROCEDURE
Minor Compressor Repair Procedures
The following instructions for removal of the magnetic clutch were written (and the art drawn) as a bench procedure, with the compressor assembly removed from the vehicle.
Remove or Disconnect
Tool Required:
J 34878 Pressure Plate Remover
1. Pressure plate nut.
2. Pressure plate, using a J 34878 pressure plate remover.
3. Drive clutch snap ring and shim, using the appropriate snap ring pliers.
4. Drive clutch. Tap off with plastic hammer if necessary.
Important
^ Be careful not to damage pulley or drive clutch when tapping off.
5. Clutch coil lead wiring from compressor housing.
6. Snap ring, using snap ring pliers.
7. Clutch coil from compressor.
Inspect
Tool Required;
J 34029-A Digital Multimeter
^ Pressure plate for wear and scoring. Replace if necessary.
^ Drive clutch for wear and scoring. Replace if necessary.
^ Clutch coil for resistance using a J 34029-A digital multimeter. Replace if not within specification.
Standard resistance: 3.2 (± 0.2) ohms
Install or Connect
1. Clutch coil to compressor.
2. Coil snap ring.
3. Clutch coil lead wire to compressor housing.
4. Drive clutch, securing with snap ring.
5. Pressure plate to compressor shaft.
Measure
^ Clearance between clutch drive plate and pressure plate.
Standard clearance: 0.4 - 0.7 mm (0.016 - 0.028 in.)
6. Pressure plate nut.
Tighten
^ 17 N.m (13 lb.ft.)
Remove or Disconnect
Tool Required:
J 34878 Pressure Plate Remover
1. Pressure plate nut.
2. Pressure plate, using a J 34878 pressure plate remover.
3. Drive clutch snap ring and shim, using the appropriate snap ring pliers.
4. Drive clutch. Tap off with plastic hammer if necessary.
Important
^ Be careful not to damage pulley or drive clutch when tapping off.
5. Clutch coil lead wiring from compressor housing.
6. Snap ring, using snap ring pliers.
7. Clutch coil from compressor.
Inspect
Tool Required;
J 34029-A Digital Multimeter
^ Pressure plate for wear and scoring. Replace if necessary.
^ Drive clutch for wear and scoring. Replace if necessary.
Clutch Coil Inspection:
^ Clutch coil for resistance using a J 34029-A digital multimeter. Replace if not within specification.
Standard resistance: 3.2 (± 0.2) ohms
Install or Connect
1. Clutch coil to compressor.
2. Coil snap ring.
3. Clutch coil lead wire to compressor housing.
4. Drive clutch, securing with snap ring.
5. Pressure plate to compressor shaft.
Measure Clearance:
Measure
^ Clearance between clutch drive plate and pressure plate.
Standard clearance: 0.4 - 0.7 mm (0.016 - 0.028 in.)
6. Pressure plate nut.
Tighten
^ 17 N.m (13 lb.ft.)
Factory Service Tools
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.