Install clutch coil on compressor using match marks. Install snap ring with beveled side away from compressor. Secure clutch coil lead to compressor front cover and connect lead to thermal limiter switch.
Using Installer (C-6871), install pulley assembly. Install snap ring with beveled side away from compressor. Install compressor shaft key and original shims. Using Driver C-6463 and a hammer, install clutch plate.

NOTE: When installing a new clutch onto a new compressor, use 0.040" (1.0 mm), 0.020" (0.5 mm), and 0.005" (0.13 mm) shims provided with NEW clutch.

Install compressor shaft center nut and tighten to 10 ft. lbs. (14 N.m). Measure air gap between clutch plate and pulley surface. Air gap should be 0.016-0.031" (0.41-0.79 mm). Add or subtract shims as necessary.
Ensure air gap is consistent around clutch. If air gap is not consistent, lightly pry up or tap down at points of variation as necessary. Install compressor and tighten mounting bolts to 30 ft. lbs. (40 N.m). Install drive belt. Connect clutch connector and negative battery cable.
After completing compressor clutch installation, start engine. Set A/C-heater control to recirculated air mode and high blower motor speed. Set engine speed to 1500-2000 RPM. Cycle compressor on for 5 seconds and off for 5 seconds, about 20 times to break-in new clutch.

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.

Safety Warning

Clutch Assembly: Installation