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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 >> Installation ("S" Series)

Installation ("S" Series)

  1. Position the A/C compressor clutch coil so that the electrical connector is aligned with the indent in the compressor front head.
  2. Install the 3 A/C compressor clutch coil screws. Tighten the clutch coil-to-compressor screws to 44 INCH Lbs. (5 N.m).
  3. Place the drive plate installer on the installation bolt and insert it through the center of the pulley. See Figure. Thread the installation bolt into the end of the A/C compressor shaft and finger tighten.
  4. Finger tighten the nut on the installation bolt to align the pulley to the A/C compressor. While holding the end of the bolt, tighten the nut until the pulley bottoms out on the A/C compressor. See Figure.
  5. Loosen the nut and remove the pulley installation bolt.
  6. Install the snap ring with the tapered side out using the snap ring pliers. See Figure.
  7. Install the shims from the old drive plate opening to the NEW drive plate opening.
  8. Position the clutch drive plate on the compressor shaft making sure the splines line up. Press the shaft into place.
  9. Position the screwdriver between the 2 vibration dampeners on the front of the clutch face and install the clutch bolt.
    NOTE: After tightening the center bolt, check to make sure that the pulley rotates smoothly by spinning it.
  10. Install the center bolt and tighten the compressor clutch drive plate-to-compressor center bolt to 115 INCH Lbs. (13 N.m).
  11. Check to make sure the clutch clearance is 0.012-0.024" (0.3-0.6 mm).
  12. If necessary, adjust the clearance by adding or removing shims provided.
  13. Remove the front bracket-to-compressor bolt and position the A/C compressor between the brackets.
  14. Install the A/C compressor to the front bracket with 3 bolts. Finger tighten the bolts.
  15. Install the A/C compressor to the rear bracket with 3 bolts. Tighten the A/C compressor front bolts-to-bracket to 36 Ft. Lbs. (49 N.m). Tighten the A/C compressor rear bolts-to-bracket to 19 Ft. Lbs (25 N.m).
    CAUTION: Make sure gaskets are installed correctly or a leak will occur. If gaskets are removed from stubs, replace with NEW gaskets. Installation steps must be performed in sequence.
    NOTE: The next 7 steps are only necessary if the vehicle is equipped with a secondary air pump reaction system (AIR).
  16. Install the air pipe onto the exhaust manifold studs.
  17. Install the air pipe into the rear air compressor bracket slot.
  18. Install the combination valve studs into the rear air compressor bracket through the air pipe flange holes.
  19. Install and tighten the nuts on the combination valve studs. Tighten the air system combination valve nuts to 62 INCH Lbs. (7 N.m).
  20. Install and tighten the nuts on the exhaust manifold studs. Tighten the air system pipe-to-exhaust manifold studs to 62 INCH Lbs. (7 N.m).
  21. Install the vacuum source hose. See Fig 2.
  22. Install the air hose.
  23. Connect A/C the compressor clutch electrical connector.
  24. Install the accessory drive belt.
  25. Start the engine and engage the A/C compressor 10-15 cycles to break-in NEW A/C compressor clutch. This cycling of the A/C compressor will match the drive plate and the pulley surfaces.
Fig 1: Identifying Compressor Clutch Connector
G00233776Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing & Installing Source Vacuum
G00233780Courtesy of GENERAL MOTORS CORP.
Fig 3: Identifying AIR Pipe Assembly
G00233777Courtesy of GENERAL MOTORS CORP.
Fig 4: Removing & Installing Compressor Bolts
G00233778Courtesy of GENERAL MOTORS CORP.
Fig 5: Installing Lower Bolt For Compressor Support
G00233779Courtesy of GENERAL MOTORS CORP.
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