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.
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HOMESERVICE MANUALSMERCURY2000MYSTIQUE GS, 2.0 3, AUTOMATICREPAIR AND DIAGNOSIS (SINGLE PAGE)HEATING, VENTILATION & A/C (HVAC)GENERAL SERVICINGHVAC SYSTEM - COMPRESSOR SERVICINGZEXEL ROTARY VANECLUTCH ASSEMBLYINSTALLATION
2000 Mercury Mystique GS, 2.0 3, Automatic
Clutch Assembly: Installation
2000 Mercury Mystique GS, 2.0 3, AutomaticSECTION Installation
- On all models, install clutch coil in original position. Ensure electrical connector is aligned with indent in front of compressor head. Tighten screws to 44 INCH lbs. (5 N.m). Place Drive Plate Installer (SA9149AC-3) and thrust bearing on installation bolt and insert through center of pulley. Finger-tighten pulley installation bolt into compressor shaft.
- Finger-tighten nut on installation bolt to align pulley to compressor. Hold end of bolt, and tighten nut until pulley bottoms on compressor. Loosen nut and remove installation bolt, thrust bearing and drive plate installer. Install snap ring with tapered side out.
- Install drive plate shims (previously removed) to clutch drive plate opening. Position drive plate on compressor shaft, ensuring splines are aligned. Press drive plate into place. Position screwdriver between 2 clutch face vibration dampeners to hold drive plate. Install drive plate center bolt and tighten to 115 INCH lbs. (13 N.m). Ensure pulley rotates smoothly with no interference.
- Using a feeler gauge, measure air gap between drive plate and pulley. Air gap should be 0.012-0.024" (0.30-0.61 mm). If air gap is not as specified, add or remove shims as necessary.
- On "S" models, install compressor onto mounting bracket. Tighten front bolts to 36 ft. lbs. (49 N.m), and rear bolts to 19 ft. lbs. (26 N.m). Connect clutch electrical connector and install accessory drive belt.
- On "L" models, ensure compressor contains the correct amount of refrigerant oil. See COMPRESSOR REFRIGERANT OIL CHECKING article. Position compressor to side of engine. Install rear and bottom compressor-to-engine bolts. Install upper bolt. When all bolts have been hand started, tighten to 15 ft. lbs. (20 N.m).
- Using NEW "O" rings, install discharge and suction lines to compressor. Tighten bolts to 12 ft. lbs. (16 N.m). Tighten suction line bolt from above. Evacuate and charge system.
- On all models, start engine and allow to idle. Turn A/C on and cycle A/C compressor on and off 10-15 times to break-in clutch drive plate and pulley assembly.
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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.