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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 >> ZEXEL (SATURN - Variable Displacement Type) >> Clutch Assembly >> Removal ("S" Series)

Removal ("S" Series)

NOTE: On Saturn "S" models, discharging A/C system and removing refrigerant lines from compressor is not necessary to service clutch assembly.
NOTE: Tools Required: Puller Center (SA9149AC-2), Snap-On™ tool S8190A and Drive Plate Installer (SA9149AC-3).
  1. Remove the accessory drive belt from the compressor clutch pulley by rotating the belt tensioner clockwise using a 9/16" (14 mm) wrench. Snap-On™ tool S8190A or equivalent can be used.
  2. Disconnect the A/C compressor clutch electrical connector. See Figure.
    NOTE: The next 7 steps are only necessary if the vehicle is equipped with a secondary air pump reaction system (AIR).
  3. Remove the nuts from the combination valve studs.
  4. Remove the air hose.
  5. Remove the vacuum source hose. See Figure. There is no need to disconnect the internal vacuum hose for this procedure.
  6. Remove the combination valve and gasket from the rear air compressor bracket.
  7. Position the combination valve and gasket away from the A/C compressor bracket.
  8. Remove the air pipe nuts from the exhaust manifold studs.
  9. Remove the air pipe. See Figure.
  10. Remove the rear A/C compressor-to-engine bracket bolts. See Figure.
  11. Remove the front A/C compressor-to-engine bracket bolts.
    CAUTION: Ensure that A/C discharge line DOES NOT change position and/or loosen at the condenser connection due to moving discharge line. Failure to ensure a tight connection will result in a system refrigerant leak.
  12. With the A/C lines still attached, lift the A/C compressor upward and install one front bolt through the front engine bracket top hole and bottom rear mounting ear of the A/C compressor. See Figure. Tighten the bolt so that the A/C compressor is supported by the bracket.
  13. Position a screwdriver between 2 vibration dampeners on the front of the clutch face and remove the clutch bolt. See Figure.
    NOTE: Be careful not to lose shims inside of the clutch drive plate opening when removing the drive plate from the compressor shaft.
  14. Position the flat blade screwdriver under the clutch drive plate and pry out evenly to remove. See Figure.
  15. Using external snap ring pliers, remove the snap ring. See Figure.
    CAUTION: DO NOT remove pulley without puller adapter. If A/C compressor shaft is pressed on, A/C compressor will be damaged.
  16. Position the tool puller center on the end of the A/C compressor shaft.
    NOTE: Make sure to hook the puller jaw behind the pulley.
  17. Install the 3-jaw puller on the A/C compressor pulley. See Figure. Tighten the center bolt to remove the pulley assembly.
    NOTE: To enable easier removal of the screws, lightly tap on the end of the screwdriver with a plastic hammer.
  18. Remove the 3 A/C compressor clutch coil screws and remove the A/C compressor clutch coil. See Figure.
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