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A/C Compressor Clutch: Installation

WARNING: This page is about a different car, the 2004 Dodge Sprinter. However, it is still accessible from the selected car via links, so may be relevant.
  1. Align the dowel pin on the back of the clutch field coil with the hole in the compressor front cover, and position the clutch coil onto the compressor. Be certain that the cluch coil wire harness leads are properly oriented and routed so that they are not pinched between the compressor front cover and the clutch coil.
    NOTE: A new snap ring must be used to secure the clutch coil to the compressor. The bevel side of the snap ring must face outward.
  2. Using snap ring pliers (Special Tool C-4574 or equivalent), install the external snap ring that secures the clutch coil to the front cover of the compressor. The bevel side of the snap ring must be facing outward and both snap ring eyelets must be oriented to the right or left of the clutch coil dowel pin on the compressor. Be certain that the snap ring is fully and 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 compressor front cover.
  3. Install and tighten the screw that secures the clutch coil wire harness connector bracket and ground clip to the top of the compressor housing.
  4. Install the pulley onto the front of the compressor. If necessary, place a block of wood on the friction surface and tap gently with a hammer (Fig 1 ).
    CAUTION: Do not mar the friction surfaces of the pulley.
  5. Using snap ring pliers (Special Tool C-4574 or equivalent), install the external snap ring (bevel side facing outward) that secures the clutch pulley to the front cover of the compressor. Be certain that the snap ring is properly fully and properly seated in the groove.
    Fig 1: Installing Pulley Assembly
    G03566162Courtesy of DAIMLERCHRYSLER CORP.
  6. If the original clutch plate and clutch pulley are to be reused, reinstall the original shim(s) on the compressor shaft against the shoulder. If a new clutch plate and/or clutch pulley are being used, install a trial stack of shims 1.0 mm (0.040 in.) thick on the compressor shaft against the shoulder.
  7. Install the clutch plate onto the compressor shaft.
  8. Install and tighten the compressor shaft bolt. If necessary, a band-type oil filter wrench or a strap wrench can be placed around the clutch plate to aid in bolt tightening. Tighten the bolt to 17.5 N.m (155 in. lbs.).
    NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is still correct. Spin the pulley before performing a final check of the air gap.
  9. If a new clutch plate and/or clutch pulley are being installed, the air gap between the clutch plate and clutch pulley must be checked (Refer to STANDARD PROCEDURE  ).
  10. Install the retainer that secures the compressor clutch coil lead to the top of the compressor.
  11. Reconnect the engine wire harness connector to the clutch coil lead on the top of the compressor.
  12. Reinstall the serpentine accessory drive belt (Refer to INSTALLATION ).
  13. Reconnect the battery negative cable.
  14. If a new clutch plate and/or clutch pulley are being installed, the new clutch components must be burnished (Refer to A/C COMPRESSOR CLUTCH BREAK-IN  ).
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