OEM 2004 Chevrolet Malibu A/C Clutch

2004 Chevrolet Malibu Parts Questions & Experts Answers

• Q: How to replace the A/C Clutch assembly on 2004 Chevrolet Malibu?

  A: If you want to change the compressor clutch assembly, you will first need to gather certain tools: universal spanner wrench (J 37872) and snap ring pliers (J 6083). Start by lifting up the vehicle and then take off the right front fender liner, the right radiator air deflector retainers, and the right radiator air deflector. Then remove the engine Drive Belt, paying attention to the fact that the a/c system does not need to be discharged. Continue to take out the compressor mounting bolts and take the compressor out of the engine leaving the compressor line connected removing the three adjustable dowels from the universal spanner wrench (J 37872) and insert three 5/16 x 1 inch bolts for its mounting. Discard the air conditioner compressor clutch plate bolt and use the universal spanner wrench (J 37872) to secure the compressor clutch plate to the air conditioner assembly as you remove it. Remove the pulley with snap ring pliers (J 6083) and snap ring. Use snap ring pliers (J 6083) to remove the compressor clutch coil snap ring prior to removal of compressor clutch coil. For installation, clean the threads of clutch plate bolt with an m6x1.0 tape and clean away debris by using compressed air. Mount the compressor clutch coil and its snap ring with the help of the snap ring pliers (J 6083), before the compressor pulley and its snap ring are mounted. Put small amounts of an oil to the 0.4 mm (0.016')sized air gap shim and place it inside clutch drive plate before attaching the compressor clutch plate. Make sure that when the drive plate is rotated, it does not rub against the pulley, and measure the air gap between the pulley and the drive plate, adjust the shims to have 0.3-0.6 mm (0.012-0.024 in) air gap. Apply the clamp load by installing the new clutch drive plate bolt with colored adhesive on at least five threads, and apply 12 n.m (106 lb in) torque with the universal spanner wrench (J 37872) to hold the compressor clutch plate. Reinstall the compressor back on to the engine, and fastening it by tightening the mounting bolts to 50 n.m (37 lbft) and then proceed with the engine Drive Belt. Lastly, make sure the radiator air deflectors are installed correctly to hold optimum a/c and engine cooling performance, reinstall the right radiator air deflector, its retainers, the right front fender liner, and lower the vehicle.