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Home >> Ford >> 2002 >> Crown Victoria Base, 4.6 9 >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> HVAC Systems - Compressor Servicing >> SANDEN TRS-90 Scroll >> Clutch Assembly >> Installation

Clutch Assembly: Installation

  1. Install clutch field coil and snap ring.
  2. Install clutch coil wire harness retaining clip on the front of the compressor and tighten the screw.
  3. Align rotor assembly squarely on the front compressor housing hub.
  4. Install pulley bearing assembly with Installer. See Fig 8. Thread installer on the shaft, then turn the nut until the pulley assembly is seated.
  5. Install external snap ring with the bevel side of the snap ring facing outward. Verify snap ring is seated.
  6. Install compressor with the original clutch shims on the compressor shaft.
  7. Install clutch plate with driver. See Fig 9. Install the shaft nut and tighten to 10.5 Ft. Lbs. (14.4 N.m).
  8. Check clutch air gap with a feeler gauge. See Fig 10. If air gap does not meet specification 0.016-0.031" (0.41-0.79 mm) add or subtract shims as required.
    NOTE: If air gap is not consistent around the clutch, lightly pry up at the minimum variations and lightly tap down at the maximum variation point.
    NOTE: When installing a NEW clutch onto a compressor that previously did not have a clutch, use the shims 0.040, 0.020, and 0.005" (1.0, 0.50, and 0.13 mm) provided with the NEW clutch.
  9. Position compressor on the mounting bracket and install bolts. Tighten bolts to 30 Ft. Lbs. (41 N.m).
  10. Plug in compressor clutch harness.
  11. Install serpentine drive belt.
  12. Install negative battery cable.
    13. NOTE: This procedure will seat (burnishing) friction surfaces and provide a higher clutch torque capability. This is only necessary on a NEW clutch.
  13. Start engine, set system to A/C mode, run engine at 1500-2000 RPM, and blower speed on high. Cycle the NEW A/C clutch 20 times (5 seconds ON and 5 seconds OFF).
Fig 1: Removing Shaft Nut, Using Spanner Wrench
G00228423Courtesy of CHRYSLER CORP.
Fig 2: Removing Compressor Clutch Assembly
G00228424Courtesy of CHRYSLER CORP.
Fig 3: Removing & Installing Pulley Snap Ring
G00228425Courtesy of CHRYSLER CORP.
Fig 4: Installing Pulley Puller
G00228426Courtesy of CHRYSLER CORP.
Fig 5: Removing Pulley Assembly
G00228427Courtesy of CHRYSLER CORP.
Fig 6: Removing Coil Wire Harness
G00228428Courtesy of CHRYSLER CORP.
Fig 7: Removing & Installing Coil Snap Ring
G00228429Courtesy of CHRYSLER CORP.
Fig 8: Installing Pulley Assembly
G00228430Courtesy of CHRYSLER CORP.
Fig 9: Installing Clutch Plate
G00228431Courtesy of CHRYSLER CORP.
Fig 10: Measuring Clutch Air Gap
G00228432Courtesy of CHRYSLER CORP.
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