HVAC System - Compressor Servicing Ford Explorer Sport Trac I

FORD FS-10 10-CYLINDER

Removal

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. See RECOVERY/EVACUATION & RECHARGING in «GENERAL SERVICING PROCEDURES»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing) article in GENERAL SERVICING. Remove A/C compressor. Remove the clutch shaft bolt. Hold the A/C clutch hub with the special tool. (Scheme 1)
2. Remove the bolt.
3. Remove the A/C clutch and the A/C clutch hub spacer. Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft. Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft. (Scheme 2)
4. Remove pulley snap ring. (Scheme 3)
5. Remove the A/C clutch pulley assembly. (Scheme 4) Note location of clutch coil electrical connector.
6. Remove the A/C clutch field coil. Note the location of the A/C clutch field coil electrical connector. Install the special tool on the nose opening of the A/C compressor. Install the special tools. (Scheme 5) Remove the A/C clutch field coil.

Installation

1. Clean the A/C clutch field coil and pulley mounting surfaces.
2. Install the A/C clutch field coil: Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned. Place the special tool on the A/C clutch field coil. (Scheme 6) Use the special tool to install the A/C clutch field coil until bottomed completely against the A/C compressor.
3. Install the A/C clutch pulley.
4. Install the pulley snap ring with the bevel side out.
5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening.
6. Install the A/C clutch.
7. Install the bolt: Hold the A/C clutch hub with the special tool. (Scheme 7) Tighten the bolt to 115 INCH Lbs. (13 N.m)
8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. (Scheme 8)
9. Install the A/C compressor. See appropriate procedure.

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. See «RECOVERY/EVACUATION & RECHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing) in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Remove compressor. Remove compressor clutch assembly. See «CLUTCH & CLUTCH FIELD COIL»(/ford/explorer-sport-trac/i-2000-2005/remont/ac-compressor/#hvac-system-compressor-servicing).
2. Remove the shaft seal felt from the nose of the A/C compressor with the special tool. (Scheme 10)
3. Clean the compressor nose area.
4. Insert the tip of the special tool into one of the snap ring eyes.
5. Rotate the special tool to position the tool tip and the snap ring eye closest to the A/C compressor shaft. (Scheme 11)
6. Pull the special tool up quickly while keeping the tool shaft against the side of the nose opening and remove the snap ring. (Scheme 12)
7. Engage the special tool into the inside diameter of the shaft seal. (Scheme 13)
8. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal. (Scheme 14)
9. Pull the seal from the A/C compressor. (Scheme 15)

1. Clean the A/C compressor nose area.
2. Place the shaft seal on the special tool. (Scheme 16) Lubricate the shaft seal and the special tool with PAG oil or equivalent.
3. Position the shaft seal and the special tool over the A/C compressor shaft. (Scheme 17)
4. Push the shaft seal onto the A/C compressor shaft with the special tool until seated. (Scheme 18)
5. Install the shaft seal snap ring. (Scheme 19)
6. Install the shaft seal felt. (Scheme 20)
7. Install the A/C clutch. See «CLUTCH & CLUTCH FIELD COIL»(/ford/explorer-sport-trac/i-2000-2005/remont/ac-compressor/#hvac-system-compressor-servicing).
8. Leak test the system. See «LEAK TESTING»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__leak-testing) in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

1. Remove the A/C compressor. See «REMOVAL AND INSTALLATION»(ref-194554-S35088042272005092800000).
2. Remove the A/C clutch plate retaining nut. Using the special tool, hold the A/C clutch plate and remove the nut. (Scheme 21)
3. Remove the A/C clutch plate. (Scheme 22)
4. Remove the A/C clutch plate spacer.
5. Remove the A/C clutch pulley snap-ring.
6. Using the special tool, remove the A/C clutch pulley. (Scheme 23)
7. Note the location of the A/C clutch field coil connector.
8. Remove the A/C clutch field coil snap-ring. (Scheme 24)
9. Remove the A/C clutch field coil. (Scheme 25)

1. Clean the A/C compressor, A/C clutch field coil and the A/C clutch pulley mounting surfaces.
2. Align and install the A/C clutch field coil to the A/C compressor. (Scheme 25)
3. Install the A/C clutch field coil snap-ring. (Scheme 24)
4. Install the A/C clutch pulley.
5. Install the A/C clutch pulley snap-ring with the bevel side up.
6. Install one nominal thickness A/C clutch plate spacer onto the A/C compressor shaft.
7. Install the A/C clutch plate.
8. Install the clutch plate retaining nut. Using the special tool, hold the A/C clutch plate and tighten the nut to 13 Ft. Lbs. (18 N.m).
9. Measure and adjust (if necessary) the A/C clutch air gap by removing or adding A/C clutch plate spacers. (Scheme 26)
10. Install the A/C compressor. See «REMOVAL AND INSTALLATION»(ref-194554-S35088042272005092800000).

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

SHAFT SEAL

Shaft seal is not serviceable. If excessive oil is present on pulley and plate friction surfaces or on compressor shaft nose area, replace compressor.

COMPRESSOR CLUTCH PLATE & HUB ASSEMBLY

Note. Tools Required: Compressor Holding Fixture (J-34992) - except V5 and V7 compressors. Compressor Holding Fixture (J-41790) - with V5 and V7 compressors. hub and drive plate remover/installer (J-33013-B).

1. Clamp the compressor holding fixture in a vise.
2. Use thumb screws in order to attach the compressor to the holding fixture.
3. Ensure that the center screw forces the tip to thrust against the end of the shaft.
4. Thread the hub and drive plate remover/installer into the hub.
5. While holding the body of hub and drive plate remover/installer of the remover with a wrench, turn the center screw into the remover body in order to remove the clutch plate and hub assembly. (Scheme 27)
6. Remove the shaft key. Retain the shaft key for reassembly.

1. Install the shaft key into the hub key groove. Allow the key to project approximately 0.125" (3.2 mm) out of the keyway. The shaft key curves slightly in order to provide an interference fit in the hub key groove.
2. Clean the clutch plate and the clutch rotor.
3. Align the shaft key with the shaft keyway.
4. Place the clutch plate and the hub assembly onto the compressor shaft. (Scheme 28)
5. Remove the forcing tip on the hub and drive plate remover/installer.
6. Reverse the body direction on the center screw.
7. Install the hub and drive plate remover/installer with the bearing.
8. Back off the body of the hub and drive plate remover/installer as necessary in order to permit the center screw to be threaded onto the end of the compressor shaft.
9. Hold the center screw with a wrench. (Scheme 28)
10. Tighten the hex portion of the hub and drive plate remover/installer body in order to press the hub onto the shaft.
11. Tighten the body several turns.
12. Remove the installer. Ensure that the shaft key remains in place in the keyway.
13. Install the clutch plate and hub assembly to the final position. Ensure that the air gap between frictional surfaces of the clutch plate and clutch rotor measures 0.20-0.30" (0.50-0.76 mm).
14. Remove the hub and drive plate remover/installer.
15. Verify proper positioning of the shaft key. Ensure that the shaft key is even with or slightly above the clutch hub.
16. Spin the pulley rotor by hand in order to verify that the rotor does not rub against the clutch drive plate.

Scheme 27

Scheme 28

COMPRESSOR CONTROL VALVE (VARIABLE DISPLACEMENT COMPRESSORS ONLY)

Note. Tools Required: Compressor Holding Fixture (J-41790).

1. Install the compressor onto the compressor holding fixture.
2. Remove the compressor control valve retaining ring using internal snap ring pliers. (Scheme 29)
3. Remove the compressor control valve from the compressor.

1. Coat the control valve O-rings with clean 525 viscosity refrigeration oil.
2. Push the compressor control valve into the compressor with thumb pressure. (Scheme 29)
3. Using internal snap ring pliers, install the compressor control valve retaining ring.
4. Ensure that the retaining ring is properly seated in the ring groove.
5. Remove the compressor from the compressor holding fixture.

Scheme 29

COMPRESSOR PRESSURE RELIEF VALVE

Note. Tools Required: Compressor Holding Fixture (J-41790).

Removal & Installation

Install the compressor onto the compressor holding fixture. Remove the pressure relief valve from the rear head of the compressor. (Scheme 30) To install, reverse removal procedure.

Scheme 30

CLUTCH ROTOR/BEARING

Note. Tools Required: External Snap Ring Pliers (J-6083) Puller Pilot (J-33023-A) Compressor Pulley Puller (J-41552) Driver Handle (J-29886) Bearing Remover (J-9398-A) External Snap Ring Pliers (J-6083) Puller Pilot (J-33023-A) Compressor Pulley Puller (J-41552) Driver Handle (J-29886) Support Block (J-21352-A) Bearing Installer (J-9481-A) Pulley Bearing Staking Tool (J-33019) Pulley And Bearing Assembly Installer (J-33017) Puller Bar (J-8433-1) Forcing Screw (J-8433-3) Compressor Holding Fixture (J-34992) - Except V7 Compressor Compressor Holding Fixture (J-41790) - With V7 Compressor

1. Remove the clutch plate and hub assembly. See «COMPRESSOR CLUTCH PLATE & HUB ASSEMBLY»(/ford/explorer-sport-trac/i-2000-2005/remont/ac-compressor/#hvac-system-compressor-servicing__compressor-clutch-plate-hub-assembly).
2. Use the snap ring pliers in order to remove the following components: The pulley rotor. The bearing assembly retaining ring. (Scheme 31)
3. Install the puller pilot to the front head. (Scheme 32)
4. Install the compressor pulley puller down into the inner circle of slots in the rotor.
5. Turn the compressor pulley puller clockwise in the slots in the rotor. (Scheme 33)
6. Perform the following steps in order to remove the pulley rotor and bearing assembly: Hold the compressor pulley puller in position. Tighten the puller screw against the puller guide. Remove the pulley rotor and bearing assembly.
7. Use the following procedure in order to properly support the rotor hub during bearing removal in order to prevent pulley rotor damage: Remove the forcing screw from the compressor pulley puller. Ensure that the puller tangs still engage in the rotor slots. Invert the assembly onto a solid flat surface or blocks.
8. Use the bearing remover and the driver handle in order to drive the bearing out of the rotor hub.

Note. DO NOT support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face will be bent.

1. Place the pulley rotor on the support block in order to fully support the rotor hub during bearing installation. (Scheme 34)
2. Use the following tools in order to align the NEW bearing squarely with the hub bore: Compressor Pulley Puller Bearing Installer Driver Handle
3. Drive the bearing fully into the hub. The installer will apply force to the outer race of the bearing, if used as shown. (Scheme 34)
4. Place the pulley bearing staking tool in the hub bore. (Scheme 35)
5. Shift the rotor and bearing assembly on the support block in order to fully support the hub under the staking pin location. Use a heavy-duty rubber band in order to hold the stake pin in the guide. Properly position the stake pin in the guide after each impact on the pin.
6. Strike the staking pin with a hammer until a metal stake, similar to the original, forms down to but not touching the bearing.
7. Stake 3 locations on the bearing race 120 degrees apart as shown. (Scheme 36)
8. With the compressor mounted on the compressor mounting fixture, position the pulley rotor and the bearing assembly on the front head.
9. Position the pulley and bearing assembly installer and the puller pilot directly over the inner race of the bearing. (Scheme 37)
10. Position the puller bar on the pulley and bearing assembly installer.
11. Assemble the 2 through bolts and the washers through the puller bar slots.
12. Thread the through bolts into the compressor holding fixture. ensure that the thread of the through bolts engage the full thickness of the compressor holding fixture.
13. Tighten the center screw in the puller bar in order to force the pulley rotor and bearing assembly onto the compressor front head. if the pulley and bearing assembly installer slips off direct in-line contact with the inner race of the bearing, perform the following steps: Loosen the forcing screw. Realign the installer and the pilot in order to ensure that the pulley and bearing assembly installer properly clears the front head.
14. Use the external snap ring pliers in order to install the pulley rotor and the retaining ring. (Scheme 31)
15. Install the clutch plate and hub assembly.

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

HIGH PRESSURE SWITCH

Note. Tools Required: Snap Ring Pliers (J-5403) O-Ring Remover (J-9553-01) Halogen Leak Detector (J-39400-A)

1. Recover the refrigerant the system. See «RECOVERY/EVACUATION & RECHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing) in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.
2. Clean the control A/C high pressure switch area before removing the snap ring. (Scheme 38)
3. Disconnect the electrical connector from the A/C high pressure switch.
4. Remove the A/C high pressure switch snap ring using a pair of 90 degree angle pliers or Snap Ring Pliers.
5. Remove the A/C high pressure switch from the compressor. (Scheme 38)
6. Remove the old O-ring seal from the A/C high pressure switch cavity using the O-ring remover.
7. Inspect the A/C high pressure switch cavity and the O-ring groove in the rear head for dirt or foreign material. Clean the components as necessary.

Note. If you reinstall an existing control switch in the compressor, use a NEW O-ring and a NEW retainer ring. An O-ring and a retainer ring is included in a NEW switch kit.

1. Lubricate the NEW O-ring using new 525 viscosity refrigerant oil.
2. Install the NEW O-ring into the groove in the switch cavity.
3. Lubricate the control switch housing using new 525 viscosity refrigerant oil.
4. Install the switch into the switch cavity until the switch bottoms in the cavity.
5. Install the A/C high pressure switch snap ring using a pair of 90 degree angle pliers or snap ring pliers. Ensure that the high point of the curved sides is adjacent to the switch housing. Ensure that the snap ring is properly seated in the switch cavity retaining groove.
6. Evacuate and recharge the system. See «RECOVERY/EVACUATION & RECHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing) in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.
7. Leak test the fittings of the components using the halogen leak detector. See «LEAK TESTING»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__leak-testing) in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.

Scheme 38

Scheme 39

Scheme 40

Note. General Motors no longer authorizes replacing the compressor shaft seal on Delphi-Harrison compressors.

MITSUBISHI ASTT

Note. No service procedures are available for this compressor. If service is required, replace the compressor.

MITSUBISHI SCROLL

Note. No service procedures are available for this compressor. If service is required, replace the compressor.

CLUTCH ASSEMBLY

Note. Tools Required: Clutch Plate Holder/Remover (J-41384).

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. See «RECOVERY/EVACUATION & RECHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing) in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Remove A/C compressor. Drain, measure and discard refrigerant oil from compressor.
2. Using clutch plate holder/remover remove clutch plate nut, washer and clutch plate from compressor drive shaft. Discard clutch plate nut. Remove clutch pulley snap ring and shim. Using a plastic mallet, gently tap and remove clutch pulley. Remove clutch coil wire retainer from compressor. Remove clutch coil snap ring and clutch coil. (Scheme 41)
3. Install clutch coil and snap ring. Attach clutch coil wire retainer to compressor. Install clutch pulley, snap ring and shim. Install clutch plate to compressor shaft. Measure air gap between clutch pulley and clutch plate.
4. Air gap should be 0.012-0.020" (0.30-0.51 mm). Add or remove shims as necessary. Install washer and NEW compressor shaft nut. Tighten compressor shaft nut to 11-15 Ft. Lbs. (15-20 N.m). After repairs, add NEW refrigerant oil to compressor equal to amount drained. To complete installation, reverse removal procedure.

Note. Tools Required: Shaft Seal Remover/Installer (J-33942-B) and Shaft Seal Protector (J-34614).

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove compressor. Drain, measure and discard refrigerant oil from compressor. Remove clutch plate, clutch pulley, shims, and clutch coil. See «CLUTCH ASSEMBLY»(/ford/explorer-sport-trac/i-2000-2005/remont/ac-compressor/#hvac-system-compressor-servicing). (Scheme 41)
2. Using a flat-blade screwdriver, remove felt ring and felt washer from front housing. Remove shaft key and shaft seal snap ring. Insert compressor shaft seal remover/installer into seal. Turn seal remover/installer until contact with notches in seal is made. Remove shaft seal.

1. Install compressor shaft seal protector onto compressor shaft. Lubricate NEW shaft seal with refrigerant oil. DO NOT touch sealing surfaces. Engage seal remover/installer into seal notches and install seal onto compressor shaft. Remove seal protector and remover/installer.
2. Install seal snap ring. Install felt washer and felt ring. Install clutch plate, clutch pulley, shims, and clutch coil. See «CLUTCH ASSEMBLY»(/ford/explorer-sport-trac/i-2000-2005/remont/ac-compressor/#hvac-system-compressor-servicing). (Scheme 41) After repairs, add refrigerant oil to compressor equal to amount drained. To complete installation, reverse removal procedure. Perform leak test.

Scheme 41

Note. This procedure is for GM vehicles. Chrysler does not provide any compressor repair information. Compressor clutch can be serviced in vehicle, (on most vehicles) without discharging A/C system. If compressor is off the vehicle, disregard the removal and installation procedures.

Note. Clutch plate and clutch pulley are a mated set and can not be replaced separately. Clutch coil can be replaced separately.

1. Raise and suitably support the vehicle (if necessary).
2. Remove the engine protection shield.
3. Install a ratchet into the A/C belt tensioner adapter opening.
4. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt. (Scheme 42)
5. Remove the A/C belt from the A/C compressor.
6. Slowly release the tension on the A/C belt tensioner.
7. Remove the clutch plate retaining bolt.
8. Remove the clutch plate assembly. (Scheme 43)
9. Remove the clutch hub/bearing snap ring.
10. Remove the clutch hub/bearing assembly.
11. Remove the snap ring from the clutch coil.
12. Remove the clutch coil from the A/C compressor.

1. Install the clutch coil to the A/C compressor.
2. Install the snap ring to the clutch coil.
3. Install the clutch hub/bearing assembly. (Scheme 43)
4. Install the clutch hub/bearing snap ring.
5. Install the clutch plate assembly.
6. Install the clutch plate retaining bolt. Tighten the bolt to 13 Ft. Lbs. (18 N.m).
7. Install a ratchet into the A/C belt tensioner adapter opening.
8. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt.
9. Install the A/C belt to the A/C compressor.
10. Slowly release the tension on the A/C belt tensioner.
11. Remove the ratchet from the A/C belt tensioner.
12. Install the engine protection shield.
13. Lower the vehicle (if necessary).

Scheme 42

Scheme 43

Note. The shaft seal is not serviceable. If seal is leaking, the compressor must be replaced.

Removal (All Models Except Grand Cherokee)

Note. The refrigerant system can remain fully-charged during compressor clutch, pulley, or coil replacement. The compressor clutch can be serviced in the vehicle (most vehicles).

1. Disconnect and isolate battery negative cable.
2. Remove the serpentine drive belt.
3. Unplug the compressor clutch coil wire harness connector.
4. Remove the bolts that secure the compressor to the mounting bracket.
5. Remove the compressor from the mounting bracket. Support the compressor in the engine compartment while servicing the clutch (when necessary).
6. Remove the compressor shaft bolt. (Scheme 44) A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal.
7. Tap the clutch plate with a plastic hammer and remove clutch plate and shim(s). (Scheme 45)
8. Remove pulley retaining snap ring with Snap Ring Pliers, and slide pulley assembly off of compressor. (Scheme 46)
9. Remove coil wire bracket/ground clip screw and wire harness.
10. Remove snap ring retaining field coil onto compressor housing. (Scheme 47) Slide field coil off of compressor housing.

Installation (All Models Except Grand Cherokee)

1. Align pin in back of field coil with hole in compressor end housing, and position field coil into place. Make sure that lead wires are properly routed, and fasten the diode and coil wire bracket with retaining screw.
2. Install field coil retaining snap ring with snap ring pliers. Press snap ring to make sure it is properly seated in the groove.
3. Install pulley assembly to compressor. If necessary, tap gently with a block of wood on the friction surface. (Scheme 48)
4. Install pulley assembly retaining snap ring (bevel side outward) with snap ring pliers. Press the snap ring to make sure it is properly seated in the groove.
5. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be used. If not, place a trial stack of shims, 0.10" (2.54 mm) thick, on the shaft against the shoulder.
6. Install front plate assembly onto shaft.
7. If installing a NEW front plate and/or pulley assembly, the gap between front plate and pulley face must be checked. Use the following procedure: Attach a dial indicator to front plate so that movement of the plate can be measured. With the dial indicator zeroed on the front plate, energize the clutch and record the amount of movement. The readings should be 0.014-0.026" (0.35-0.65 mm). If proper reading is not obtained, add or subtract shims until desired reading is obtained.
8. Install compressor shaft bolt. Tighten to 135-175 INCH Lbs. (15.5-19.5 N.m).
9. Check air gap in 4 or more places to verify if air gap is still correct. Spin pulley for final check. Install the accessory drive belts.

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Removal (Grand Cherokee)

Note. The refrigerant system can remain fully-charged during compressor clutch, pulley, or coil replacement. The compressor clutch can be serviced in the vehicle.

1. Disconnect and isolate the battery negative cable.
2. Remove the serpentine drive belt.
3. Remove the bolt that secures the compressor clutch to the compressor shaft. (Scheme 44) A band-type oil filter wrench may be used to secure the clutch during bolt removal.
4. Tap the clutch plate with a plastic mallet to release it from the splines on the compressor shaft. Remove the clutch plate and shim(s) from the compressor shaft. (Scheme 45)
5. Remove the external snap ring that secures the compressor clutch pulley to the nose of the compressor front housing with Snap Ring Pliers and slide the pulley assembly off of the compressor. (Scheme 46)
6. Remove the screw and retainer from the clutch coil lead wire harness on the compressor front housing.
7. Remove the external snap ring that secures the compressor clutch coil to the nose of the compressor front housing with snap ring pliers and slide the coil assembly off of, the compressor. (Scheme 47)

Installation (Grand Cherokee)

1. Align the dowel pin on the back of the clutch field coil with the hole in the compressor front housing and press the field coil into place over the nose of the compressor.
2. Install the clutch coil lead wire harness retaining clip on the compressor front housing and tighten the retaining screw.
3. Install the clutch field coil and snap ring with Snap Ring Pliers. The bevel side of the snap ring must be facing outward. Also, both eyelets of the snap ring must be to the right or left of the pin on the compressor. Press in on the snap ring to be certain that it is properly seated in the groove. CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in a clutch failure and severe damage to the front housing of the compressor.
4. Install the pulley assembly onto the compressor. If necessary, place a block of wood on the friction surface and tap gently with a hammer. (Scheme 48) CAUTION: DO NOT mar the pulley friction surface.
5. Install the pulley assembly retaining snap ring (bevel side outward) with snap ring pliers. Press in on the snap ring to be certain that it is, properly seated in the groove.
6. If the original clutch plate assembly and pulley assembly are to be reused, the old shim(s) can be used. If not, place a stack of shims equal to the old shims on the shaft against the shoulder.
7. Install the clutch plate assembly onto the shaft.
8. With the clutch plate assembly tight against the shims, measure the air gap between the clutch plate and the pulley face with feeler gauges. The air gap should be 0.014-0.026" (0.35-0.65 mm.). If the proper air gap is not obtained, add or subtract shims as needed until the desired air gap is obtained.
9. Install the compressor shaft bolt. Tighten the bolt to 115 INCH Lbs. (13 N.m). NOTE: The shims may compress after tightening the shaft bolt. Recheck the air gap in 4 or more places to verify the air gap is still correct. Spin the pulley before performing a final check of the air gap.

Note. On 10PA17 compressor, if shaft seal is leaking compressor must be replaced.

Removal & Installation (General Motors)

Compressor components are not serviceable. If there is a compressor, compressor clutch or shaft seal failure, replace compressor and compressor clutch as an assembly.

SANDEN SD-7H15 7-CYLINDER

Note. On Cherokee, Dakota, Durango and Ram Pickup, compressor clutch can be serviced in vehicle, without discharging A/C system.

Note. Tools Required: Rotor Puller (Special Tool C-6141-1 In Kit 6460) Spanner Wrench (Special Tool 6462 In Kit 6460) Puller Through-Bolts (Special Tool C-6461) Shaft Protector (Special Tool C-6141-2 In Kit 6460) Installer (C-6871) Driver (C-6463) Handle (Special Tool 6464 In Kit 6460)

Removal (All Models)

1. Disconnect and isolate the battery negative cable.
2. Remove the serpentine drive belt.
3. Unplug the compressor clutch coil wire harness connector.
4. Insert the 2 pins of the spanner wrench into the holes of the clutch plate. Hold the clutch plate stationary and remove the hex nut. (Scheme 49)
5. Remove the clutch plate and the clutch shims.
6. Remove the external front housing snap ring with snap ring pliers. (Scheme 59)
7. Install the lip of the rotor puller into the snap ring groove exposed in step 6, and install the shaft protector. (Scheme 50)
8. Install the puller through-bolts through the puller flange and into the jaws of the rotor puller and tighten. (Scheme 51) Turn the puller center bolt clockwise until the rotor pulley is free.
9. Remove the screw and retainer from the clutch coil lead wire harness on the compressor front housing. (Scheme 52)
10. Remove the snap ring from the compressor hub and remove the clutch field coil. (Scheme 53) Slide the clutch field coil off of the compressor hub.

Installation (Cherokee)

1. Install clutch coil and clutch coil snap ring. Install clutch coil wire harness to compressor housing. Align pulley and bearing assembly on front compressor housing hub. Using installer, press pulley and bearing assembly onto compressor housing hub. Thread installer onto compressor shaft, and tighten nut until pulley assembly is seated.
2. Install external front snap ring with beveled side facing outward. Ensure snap ring is properly seated. Install compressor shaft key and original shims. Using a plastic mallet and driver, install clutch plate on compressor shaft. Tighten compressor shaft nut to 10 Ft. Lbs. (14 N.m).
3. Using feeler gauge, measure air gap between clutch plate and pulley assembly in several areas. Air gap should be 0.016-0.031" (0.41-0.79 mm). If air gap is not within specification, adjust shim thickness as necessary. If air gap is not consistent around clutch plate, lightly pry up or tap down on clutch plate to make corrections. To complete installation, reverse removal procedure.

Installation (Dakota, Durango & Ram Pickup)

1. Install the clutch field coil and snap ring. (Scheme 53)
2. Install the clutch coil lead wire harness retaining clip on the compressor front housing and tighten the retaining screw. Care must be taken not to pinch the lead wire with the retaining clip when tightening the retaining screw.
3. Align the rotor assembly squarely on the front compressor housing hub.
4. Thread the handle into the driver. (Scheme 54)
5. Place the driver tool assembly into the bearing cavity on the rotor. Make certain the outer edge of the tool rests firmly on the rotor bearing inner race. (Scheme 55)
6. Tap the end of the driver while guiding the rotor to prevent binding. Tap until the rotor bottoms against the compressor front housing hub. Listen for a distinct change of sound during the tapping process, to indicate the bottoming of the rotor.
7. Install the external front rotor snap ring with snap ring pliers. The bevel side of the snap ring must be facing outward. Press the snap ring to make sure it is properly seated in the groove. CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in a clutch failure and severe damage to the front housing of the compressor.
8. Ensure that there is adequate clearance between the lead wire and clutch rotor.
9. Install the original clutch shims on the compressor shaft.
10. Install the clutch plate. Use the shaft protector to install the clutch plate on the compressor shaft. (Scheme 56) Tap the clutch plate over the compressor shaft until it has bottomed against the clutch shims. Listen for a distinct change of sound during the tapping process to indicate the bottoming of the clutch plate.
11. Replace the compressor shaft hex nut. Tighten the nut to 11-15 Ft. Lbs. (15-20 N.m).
12. Check the clutch air gap with a feeler gauge. If the air gap does not meet the specification, add or subtract shims as required. The air gap specification is 0.016-0.031" (0.41-0.79 mm). If the air gap is not consistent around the circumference of the clutch, lightly pry up at the minimum variations. Lightly tap down at the points of maximum variation. NOTE: The air gap is determined by the spacer shims. When installing an original, or a NEW clutch assembly, try the original shims first. When installing a NEW clutch onto a compressor that previously did not have a clutch, use 0.040, 0.020, and 0.005" (1.0, 0.50, and 0.13 mm) shims from the clutch hardware package that is provided with the NEW clutch.

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Note. Refrigerant does not have to be recovered for compressor clutch, pulley or coil replacement. The compressor clutch can be serviced in the vehicle.

Note. Tools Required: Spanner Wrench (C-4489) Puller (C-6461) Snap Ring Pliers Rotor Puller (C-6141-1) Shaft Protector (C-6141-2) Installer (C-6871) Driver (C-6463)

1. Disconnect and isolate negative battery cable.
2. Remove serpentine drive belt.
3. Unplug the compressor clutch coil wire harness connector.
4. Remove 3 compressor mounting bolts.
5. Remove compressor from mounting bracket and support compressor while servicing the clutch.
6. Insert 2 pins of the spanner wrench into the holes of the clutch plate. (Scheme 57) Hold the clutch plate stationary and remove nut.
7. Remove clutch plate with a Puller. (Scheme 58)
8. Remove compressor clutch shims.
9. Remove external front housing snap ring with snap ring pliers. (Scheme 59)
10. Install lip of the rotor puller into the external snap ring groove and install shaft protector. (Scheme 60)
11. Install puller bolts through the puller flange and into the jaws of the rotor puller and tighten. (Scheme 61) Turn the puller center bolt clockwise until the rotor pulley is free.
12. Remove screw and retainer from clutch coil wire harness on the front of the compressor. (Scheme 62)
13. Remove snap ring from compressor hub and remove clutch field coil. (Scheme 63) Slide clutch field coil off of the compressor hub.

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. (Scheme 64) 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. (Scheme 65) Install the shaft nut and tighten to 10.5 Ft. Lbs. (14.4 N.m).
8. Check clutch air gap with a feeler gauge. (Scheme 66) 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. 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).

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Note. The refrigerant system can remain fully-charged during compressor clutch, pulley, or coil replacement. The compressor clutch can be serviced in the vehicle.

Note. Rotor/pulley assembly and clutch plate are a matched pair and should be replaced together.

1. Disconnect and isolate the negative battery cable.
2. Remove the serpentine drive belt.
3. Unplug the compressor clutch coil wire harness connector.
4. Remove the clutch plate and the clutch shims. If necessary, tap the clutch plate lightly with a plastic hammer to loosen it.
5. Remove the compressor clutch pulley retaining snap ring with snap ring pliers.
6. Remove the clutch pulley assembly from the compressor. A 3 jaw pulley can be used to remove pulley. Shaft protector No. 2134A (contained in MC-91268 Universal Compressor Seal Service Tool Set) must be used to protect compressor shaft from damage. DO NOT allow pullers center screw to bear on compressor shaft. If necessary, tap the clutch pulley lightly with a plastic hammer to loosen it.
7. Remove the screw and retainer from the clutch coil lead wire harness on the compressor front housing.
8. Unplug the compressor clutch wire harness connectors from the thermal limiter switch.
9. Note the alignment of the clutch field coil assembly on the compressor before removing it for correct reinstallation.
10. Remove the snap ring that secures the clutch field coil assembly to the compressor front housing. (Scheme 67)
11. Remove the clutch field coil assembly from the compressor front housing.

Scheme 67

1. Position the back of the clutch field coil against the compressor front housing. Be certain that the locating pin on the back of the coil lines up with the indentation on the compressor front housing. This ensures the proper orientation of the coil and the wire harness.
2. Install the clutch field coil snap ring (bevel side outward) with snap ring pliers. Be certain that the snap ring is properly seated into the groove.
3. Install the clutch coil lead wire harness retaining clip on the compressor front housing and tighten the retaining screw.
4. Plug in the compressor clutch wire harness connectors to the thermal limiter switch.
5. Position the clutch pulley assembly onto the compressor. CAUTION: DO NOT mar or contaminate the clutch pulley friction surface.
6. Install the clutch pulley assembly snap ring (bevel side outward) with snap ring pliers. Be certain that the snap ring is properly seated in the groove.
7. Place a trial stack of shims, 0.027" (0.07 mm) thick, on the compressor shaft.
8. Note the machined mating splines on the compressor shaft and in the clutch plate hub. (Scheme 68)
9. Align the mating splines and install the clutch plate on the compressor shaft.
10. Install the external front rotor snap ring with snap ring pliers. The beveled side of the snap ring must be facing outward. Press the snap ring to make sure it is properly seated in the groove.
11. With the front clutch plate assembly tight against the shims, measure the air gap between the clutch plate and the pulley face with a feeler gauge. (Scheme 66) The air gap should be 0.013-0.025" (0.35-.0.65 mm). If the proper air gap is not obtained, add or subtract shims until the desired air gap is obtained.
12. Install the compressor shaft nut. Tighten the nut to 13 Ft. Lbs. (17.7 N.m).
13. The shims may compress after tightening the compressor shaft nut. Check the air gap in 4 or more places to verify that the air gap is still correct. Spin the pulley for a final check.
14. Install the serpentine drive belt.
15. Connect the negative battery cable.

Scheme 68

Shaft seal is not serviceable. If excessive oil is present on pulley and plate friction surfaces or on compressor shaft nose area, replace compressor.

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. (Scheme 69) 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. (Scheme 70) 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. (Scheme 71)
10. Remove the rear A/C compressor-to-engine bracket bolts. (Scheme 72)
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. (Scheme 73) 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. (Scheme 74) 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. (Scheme 75)
15. Using external snap ring pliers, remove the snap ring. (Scheme 76) 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. (Scheme 77) 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. (Scheme 78)

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. (Scheme 79) 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. (Scheme 80)
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. (Scheme 76)
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. (Scheme 70)
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.

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Removal ("L" Series)

Note. On Saturn "L" models, it is necessary to discharge A/C system and remove compressor from vehicle to service clutch assembly.

Note. Tools Required: Puller Center (SA9149AC-2) and Drive Plate Installer (SA9149AC-3).

1. Remove the compressor from the vehicle. See COMPRESSOR under REMOVAL & INSTALLATION in SATURN - "L" MODELS article in MANUAL A/C-HEATER SYSTEMS.
2. Using a screwdriver to prevent drive plate from turning, remove the clutch drive plate bolt. (Scheme 74) NOTE: Be careful not to lose the shims when removing the drive plate from the compressor shaft.
3. Using a screwdriver with a thin blade, pry the drive plate off of the pulley. (Scheme 75)
4. Using external snap ring pliers, remove the snap ring. (Scheme 76) NOTE: DO NOT remove pulley without puller adapter. If A/C compressor shaft is pressed on, A/C compressor will be damaged.
5. Position the puller center on the end of the A/C compressor shaft. (Scheme 77) NOTE: Ensure to hook the puller jaw behind the pulley only, not the coil.
6. Install the 3-jaw puller on the A/C compressor pulley. Tighten the center bolt to remove the pulley assembly. NOTE: To enable easier removal of screws, lightly tap on the end of the screwdriver with a plastic hammer.
7. Remove the A/C compressor clutch coil screws and remove the A/C compressor clutch coil. (Scheme 78)

Installation ("L" Series)

1. Position the A/C compressor clutch coil so that the electrical connector is aligned with the indent in compressor front head. (Scheme 78)
2. Install the A/C compressor clutch coil screws. Tighten the A/C compressor clutch coil fasteners to 44 INCH Lbs. (5 N.m).
3. Place the thrust bearing and the Drive Plate Installer on the installation bolt and insert through the center of the pulley. Thread the installation bolt into the end of A/C compressor shaft and hand tighten. (Scheme 79)
4. Hand tighten nut on the installation bolt to align the pulley to the A/C compressor. While holding the end of bolt, tighten the nut until the pulley bottoms out on the A/C compressor. (Scheme 80)
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.
7. Install the shims removed from the old drive plate into the clutch drive plate and install it onto the compressor shaft.
8. Install the drive plate bolt.
9. Using a screwdriver to hold drive plate, tighten the drive plate bolt. Tighten the A/C compressor clutch plate bolt to 106 INCH Lbs. (12 N.m).
10. Using a feeler gage, inspect to ensure the clearance is 0.012-0.024" (0.3-0.6 mm). (Scheme 81)
11. If necessary, adjust the clearance by adding shims provided with the clutch. After installing the shims, re-install the drive plate and verify the proper clearance.

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Removal (VUE)

Note. Tools Required: 3 Jaw Puller (J-25031-A) Snap Ring Pliers (SA9149AC-8) Clutch Pulley Installer (J-45504) Clutch Holding Tool (J-45267)

1. Recover the refrigerant system. See «RECOVERY/EVACUATION & RECHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing) in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Remove the compressor. See COMPRESSOR under REMOVAL & INSTALLATION in VUE article in MANUAL A/C-HEATER SYSTEMS.
2. Use the clutch holding tool to hold the disk and hub assembly. Remove the clutch nut and the disk and hub assembly. (Scheme 82)
3. Remove the spacer.
4. Use snap ring pliers to remove the pulley snap ring. (Scheme 83)
5. Use the 3 jawed puller to remove the A/C clutch pulley. (Scheme 84)
6. Remove the thermal switch bolt and the hold-down bracket. (Scheme 85) NOTE: It may be necessary to pry the switch lightly with a small screwdriver.
7. Lift out the thermal switch while lightly twisting and pulling up on the sensor.
8. Use snap ring pliers to remove the field coil snap ring. (Scheme 86)
9. Remove the A/C clutch field coil. (Scheme 87)

Installation (VUE)

1. Clean the mounting surfaces on the A/C clutch field coil and pulley.
2. Install the A/C clutch field coil.
3. Use the snap ring pliers to install the field coil snap ring with the bevel side out. NOTE: It is important to use Saturn Sealant P/N 22681632 as a thermal conductive material. Failure to use this sealant may affect the function of the switch.
4. Clean the thermal switch pocket if necessary.
5. Apply thermal switch sealant approximately the size of a pea into the switch pocket.
6. Install the thermal switch by pushing the switch into place and wetting out the sealant, while holding the switch in place. Wipe away any excess sealant.
7. Install the thermal switch hold-down bracket and bolt. Tighten the bolt to 53 INCH Lbs. (6 N.m). NOTE: The A/C clutch bearing and pulley is a slip fit on the compressor. If correctly aligned the pulley should slip on easily. If difficulty is encountered, install using the pulley installer tool.
8. Use clutch pulley installer to align the clutch bearing/pulley assembly over the hub. Gently tap on the assembly to install.
9. Use snap ring pliers to install the pulley snap ring with the bevel side out.
10. Install the spacer. NOTE: Align the block tooth on the disk and hub assembly with the groove in the shaft.
11. Install the drive plate and nut. Use the old nut to evaluate the clearances.
12. Using a feeler gauge, verify that the clearance is 0.014-0.030" (0.35-0.75 mm).
13. If necessary, adjust the clearance by adding or removing clutch hub spacers.
14. Once the correct air gap is obtained, install a NEW clutch nut. Use clutch holding tool to hold the disk and hub assembly while tightening the nut to 14 Ft. Lbs. (19 N.m).
15. Install the compressor. See COMPRESSOR under REMOVAL & INSTALLATION in VUE article in MANUAL A/C-HEATER SYSTEMS.
16. Evacuate and charge the refrigerant system. See «RECOVERY/EVACUATION & RECHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing) in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.
17. Leak test the fittings. See «LEAK TESTING»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__leak-testing) in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

PRESSURE RELIEF VALVE

Note. Halogen Leak Detector (J-39400-A)

1. Recover the refrigerant. See «RECOVERY/EVACUATION & RECHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing) in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.
2. Raise and support the vehicle.
3. Remove pressure relief valve from compressor hose. (Scheme 88)

Note. Use R-12 refrigerant oil (mineral) to lubricate O-rings. Use of R-134a (PAG) oil will cause premature corrosion of fitting joints.

1. Lubricate the pressure relief valve O-ring with new R-12 mineral compressor oil.
2. Install the pressure relief valve to the compressor hose. (Scheme 88) Tighten the pressure relief valve to 89 INCH Lbs. (10 N.m).
3. Lower the vehicle.
4. Evacuate and charge the A/C system. See «RECOVERY/EVACUATION & RECHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing) in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.
5. Test the affected A/C joint for leaks using a leak detector. See «LEAK TESTING»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__leak-testing) in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.

Scheme 88

See also:
• GENERAL SERVICING PROCEDURES
• LEAK TESTING
• CLUTCH & CLUTCH FIELD COIL
• COMPRESSOR CLUTCH PLATE & HUB ASSEMBLY