Air Conditioning Clutch Replacement (L84, L87)

Single Use Fasteners and Components Air Conditioning Compressor and Condenser Hose Seal - Large Air Conditioning Compressor and Condenser Hose Seal - Small Accessory Drive Primary Belt Accessory Drive Auxiliary Belt Engine Oil Cooler Retainer [2x] Special Tools Engine Mechanical EN-51767-2 Universal Stretchy Belt Installer Equivalent regional tools: Special Tools Removal Procedure

1. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection

Air Conditioning Clutch Replacement (L84, L87) — figure 1

2. Air Cleaner Outlet Duct Bracket Bolt (1) » Remove
3. Remove the engine wiring harness from the air cleaner outlet duct bracket.

Air Conditioning Clutch Replacement (L84, L87) — figure 2

4. Positive Crankcase Ventilation Fresh Air Tube (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
5. Air Cleaner Outlet Duct Clamp (2) » Loosen [2x]
6. Air Cleaner Outlet Duct (3) » Remove
7. Raise and support the vehicle. Lifting and Jacking the Vehicle

Air Conditioning Clutch Replacement (L84, L87) — figure 3

8. Remove the underbody splash shield: 8.1. Underbody Splash Shield Bolt (1) » Remove [4x] 8.2. Underbody Splash Shield (2) » Remove

Air Conditioning Clutch Replacement (L84, L87) — figure 4

9. {with NZZ} Remove the underbody skid shield: 9.1. Underbody Skid Shield Bolt (1) » Remove [2x] 9.2. Underbody Skid Shield (2) » Remove

10. {without NZZ} Remove the steering gear skid shield: 10.1. Steering Gear Skid Shield Bolt (1) » Remove [2x] 10.2. Steering Gear Skid Shield (2) » Remove

Air Conditioning Clutch Replacement (L84, L87) — figure 5

11. Electrical Connector (1) @ Air Conditioning Compressor » Disconnect

Air Conditioning Clutch Replacement (L84, L87) — figure 6

Note

The accessory drive primary belt is not reusable. Some components not shown for graphic clarity.

12. Using a suitable tool, cut the accessory drive primary belt (1).
13. Accessory Drive Primary Belt (1) » Remove and DISCARD

Air Conditioning Clutch Replacement (L84, L87) — figure 7

Note

The accessory drive auxiliary belt is not reusable.

14. Using a suitable tool, cut the accessory drive auxiliary belt (1).
15. Accessory Drive Auxiliary Belt (1) » Remove and DISCARD
16. Drain the cooling system. Cooling System Draining and Filling

Air Conditioning Clutch Replacement (L84, L87) — figure 8

17. Radiator Surge Tank Outlet Hose Clip (2) » Remove [2x]
18. Radiator Surge Tank Outlet Hose (3) » Position aside

Air Conditioning Clutch Replacement (L84, L87) — figure 9

Note

Some components not shown for graphic clarity.

19. Radiator Inlet Hose Clip (2) » Remove
20. Radiator Inlet Hose Clamp (1) » Disengage — Hose Clamp Replacement Guidelines - Spring Type
21. Radiator Inlet Hose (3) @ Engine Radiator » Remove and position aside

Air Conditioning Clutch Replacement (L84, L87) — figure 10

Note

Some components not shown for graphic clarity.

22. Wiring Harness Retainer (1) » Remove [2x]
23. Electrical Connector (3) » Disconnect
24. Wiring Harness (2) » Position aside

Air Conditioning Clutch Replacement (L84, L87) — figure 11

Note

Some components not shown for graphic clarity.

25. Wiring Harness Retainer (2) » Remove [2x]
26. Electrical Connector (1) » Disconnect
27. Wiring Harness (3) » Position aside

Air Conditioning Clutch Replacement (L84, L87) — figure 12

28. Engine Oil Cooler Hose Clip (1) » Release

Air Conditioning Clutch Replacement (L84, L87) — figure 13

29. Engine Oil Cooler Retainer (2) » Remove and DISCARD [2x]
30. Engine Oil Cooler Pipe Bracket Bolt (3) » Remove

Note

Cap the engine oil cooler hose to prevent fluid loss or contamination.

31. Engine Oil Cooler Hose (1) @ Engine Radiator » Remove [2x]

Air Conditioning Clutch Replacement (L84, L87) — figure 14

32. Transmission Fluid Cooler Pipe Bolt (1) » Remove
33. Transmission Fluid Cooler Pipe Clip (2) » Remove [2x]

Air Conditioning Clutch Replacement (L84, L87) — figure 15

34. Transmission Fluid Cooler Pipe Clip (1) » Release

Air Conditioning Clutch Replacement (L84, L87) — figure 16

35. Engine Coolant Fan Bracket Bolt (1) » Remove [2x]

Air Conditioning Clutch Replacement (L84, L87) — figure 17

36. Engine Cooler Fan (1) @ Engine Radiator » Remove

Air Conditioning Clutch Replacement (L84, L87) — figure 18

37. Air Conditioning Compressor and Condenser Hose Nut (1) » Remove
38. Air Conditioning Compressor and Condenser Hose (2) » Remove
39. Air Conditioning Compressor and Condenser Hose Seal - Small (4) » Remove and DISCARD
40. Air Conditioning Compressor and Condenser Hose Seal - Large (3) » Remove and DISCARD

Air Conditioning Clutch Replacement (L84, L87) — figure 19

41. Air Conditioning Compressor Bolt (1) » Remove
42. Air Conditioning Compressor Nut (2) » Remove
43. Air Conditioning Compressor Stud (3) » Remove
44. Disconnect the electrical connector. (4)

Air Conditioning Clutch Replacement (L84, L87) — figure 20

45. Air Conditioning Compressor (1) » Remove

Air Conditioning Clutch Replacement (L84, L87) — figure 21

46. Air Conditioning Compressor Pulley Bolt (3) » Remove
47. Air Conditioning Compressor Clutch Drive Plate (2) » Remove
48. Air Conditioning Clutch Shim (1) » Remove

Air Conditioning Clutch Replacement (L84, L87) — figure 22

49. Air Conditioning Compressor Pulley Bearing Retaining Ring (5) » Remove

50. Air Conditioning Compressor Pulley (4) » Remove

51. Air Conditioning Compressor Bracket Bolt (1) » Remove

52. Air Conditioning Clutch Coil Retaining Ring (3) » Remove

53. Air Conditioning Compressor Clutch Coil (2) » Remove Installation Procedure

54. Air Conditioning Compressor Clutch Coil (2) » Install

Caution

Refer to Component Fastener Tightening Caution

2. Air Conditioning Compressor Bracket Bolt (1) » Install and tighten — Fastener Specifications
3. Air Conditioning Clutch Coil Retaining Ring (3) » Install
4. Air Conditioning Compressor Pulley (4) » Install
5. Air Conditioning Compressor Pulley Bearing Retaining Ring (5) » Install

Note

Use the original shim count as a starting point to determine the proper air gap for the air conditioning clutch plate.

6. Air Conditioning Clutch Shim (1) » Install
7. Install the air conditioning clutch shim(s) (1) as needed to achieve the appropriate air gap of 0.21–0.55 mm (0.008–0.022 in).

Air Conditioning Clutch Replacement (L84, L87) — figure 23

8. Air Conditioning Compressor Clutch Drive Plate (1) » Install
9. Air Conditioning Compressor Pulley Bolt (4) » Install and hand tighten
10. Measure the air gap between air conditioning clutch drive plate (1) and the air conditioning compressor pulley (2) using the appropriate feeler gauge (3).
11. If the air gap is out of range remove the air conditioning clutch drive plate, and add or remove shim(s) as need to achieve the appropriate air gap.
12. Repeat steps 6–10 as needed to achieve the appropriate air gap.

Caution

Refer to Fastener Caution.

13. Air Conditioning Compressor Pulley Bolt (4) » Install and tighten — Fastener Specifications

14. Air Conditioning Compressor (1) » Install

15. Air Conditioning Compressor Bolt (1) » Loosely install

16. Air Conditioning Compressor Stud (3) » Install and tighten — Fastener Specifications

17. Air Conditioning Compressor Bolt (1) » Tighten — Fastener Specifications

18. Air Conditioning Compressor Nut (2) » Install and tighten — Fastener Specifications

19. Connect the electrical connector. (4)

20. Electrical Connector (1) @ Air Conditioning Compressor » Connect

21. Air Conditioning Compressor and Condenser Hose Seal - Small (4) » Install NEW

22. Air Conditioning Compressor and Condenser Hose Seal - Large (3) » Install NEW

23. Air Conditioning Compressor and Condenser Hose (2) » Install

24. Air Conditioning Compressor and Condenser Hose Nut (1) » Install and tighten — Fastener Specifications

Air Conditioning Clutch Replacement (L84, L87) — figure 24

Note

The OEM replacement stretchy belt is packaged with a disposable installation tool and installation instructions.

25. Install the air conditioning belt following the instructions included with the belt.
26. Inspect the belt (1) for proper installation and alignment.

Air Conditioning Clutch Replacement (L84, L87) — figure 25

27. Rotate the balancer (1) an additional 360 degrees to ensure proper belt installation.

Air Conditioning Clutch Replacement (L84, L87) — figure 26

28. Position the accessory drive primary belt (4) on the belt idler pulley (2), fan and water pump pulley (3) and generator (1).

Air Conditioning Clutch Replacement (L84, L87) — figure 27

29. Install EN-51767-2 Universal Stretchy Belt Installer (1) onto the crankshaft balancer.

Air Conditioning Clutch Replacement (L84, L87) — figure 28

30. Position the accessory drive primary belt (2) on the crankshaft balancer.
31. Slowly rotate the crankshaft balancer in a clockwise direction until the accessory drive primary belt (2) fully seats on the crankshaft balancer.
32. Remove EN-51767-2 Universal Stretchy Belt Installer (1) from the crankshaft balancer.

Air Conditioning Clutch Replacement (L84, L87) — figure 29

33. Inspect the accessory drive primary belt (1) for proper installation and alignment.

Air Conditioning Clutch Replacement (L84, L87) — figure 30

34. Rotate the crankshaft balancer (1) and additional 360 degrees to ensure proper accessory drive primary belt installation.

35. Engine Cooler Fan (1) @ Engine Radiator » Install

36. Engine Coolant Fan Bracket Bolt (1) » Install and tighten [2x] — Fastener Specifications

37. Transmission Fluid Cooler Pipe Clip (1) » Secure

38. Transmission Fluid Cooler Pipe Clip (2) » Install [2x]

39. Transmission Fluid Cooler Pipe Bolt (1) » Install and tighten — Fastener Specifications

40. Engine Oil Cooler Hose (1) @ Engine Radiator » Install

41. Engine Oil Cooler Pipe Bracket Bolt (3) » Install and tighten — Fastener Specifications

42. Engine Oil Cooler Retainer (2) » Install NEW [2x]

43. Engine Oil Cooler Hose Clip (1) » Secure

Note

Some components not shown for graphic clarity.

44. Position the wiring harness. (3)
45. Electrical Connector (1) » Connect
46. Wiring Harness Retainer (2) » Install [2x]

Note

Some components not shown for graphic clarity.

47. Position the wiring harness. (2)
48. Electrical Connector (3) » Connect
49. Wiring Harness Retainer (1) » Install [2x]

Note

Some components not shown for graphic clarity.

50. Radiator Inlet Hose (3) @ Engine Radiator » Install

51. Radiator Inlet Hose Clamp (1) » Engage — Hose Clamp Replacement Guidelines - Spring Type

52. Radiator Inlet Hose Clip (2) » Install

53. Radiator Surge Tank Outlet Hose (3) » Move into position

54. Radiator Surge Tank Outlet Hose Clip (2) » Install [2x]

55. {without NZZ} Install the steering gear skid shield: 55.1. Steering Gear Skid Shield (2) » Install 55.2. Steering Gear Skid Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

56. {with NZZ} Install the underbody skid shield: 56.1. Underbody Skid Shield (2) » Install 56.2. Underbody Skid Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

57. Install the underbody splash shield: 57.1. Underbody Splash Shield (2) » Install 57.2. Underbody Splash Shield Bolt (1) » Install and tighten [4x] — Fastener Specifications

58. Air Cleaner Outlet Duct (3) » Install

59. Air Cleaner Outlet Duct Clamp (2) » Tighten [2x] — Fastener Specifications

60. Positive Crankcase Ventilation Fresh Air Tube (1) » Connect — Plastic Collar Quick Connect Fitting Service

61. Air Cleaner Outlet Duct Bracket Bolt (1) » Install and tighten — Fastener Specifications

62. Install the engine wiring harness to the air cleaner outlet duct bracket.

63. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection

64. Fill the cooling system. Cooling System Draining and Filling

65. Recharge the refrigerant. Refrigerant Recovery and Recharging

66. Inspect for refrigerant leaks. Leak Testing

67. Start the engine and check for coolant leaks.