Clutch-A/C Compressor: Installation

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Typical A/C compressor shown in illustrations.

Fig 1: Removing/Installing Clutch Coil Snap Ring

Courtesy of DAIMLERCHRYSLER CORP.

Align the dowel pin on the back of the compressor clutch field coil (2) with the hole in the front of the A/C compressor (3) and position the field coil onto the compressor. Be certain that the compressor clutch field coil wire lead is properly routed so that it is not pinched between the A/C compressor and the field coil.
CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor.

NOTE: A new snap ring must be used to secure the compressor clutch field coil to the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or to the left of the field coil dowel pin location on the A/C compressor.
Using snap ring pliers (1), install the snap ring (4) that secures the compressor clutch field coil to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented correctly.

Fig 2: Installing Pulley & Bearing Assembly
Courtesy of DAIMLERCHRYSLER CORP.

CAUTION: Be certain to position the compressor clutch field coil wire lead so that it is not damaged during A/C compressor pulley and bearing installation.

CAUTION: When installing the pulley and bearing assembly, DO NOT mar the friction surfaces of the pulley or premature failure of the clutch will result.
Install the pulley and bearing assembly (1) onto the front of the A/C compressor. If necessary, tap the pulley gently with a block of wood (2) placed on the pulley friction surface.

Fig 3: Removing/Installing External Snap Ring
Courtesy of DAIMLERCHRYSLER CORP.

CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor.

NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward.
Using snap ring pliers (2), install the snap ring (1) that secures the pulley and bearing assembly (3) to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove.

Fig 4: Identifying Compressor Shaft, Clutch Plate & Shim
Courtesy of DAIMLERCHRYSLER CORP.
If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original shim(s) (3) onto the compressor shaft (1). If a new clutch plate and pulley and bearing assembly are being used, install a trial stack of shims 2.54 mm (0.010 in.) thick onto the compressor shaft.

Fig 5: Locating A/C Compressor Shaft Bolt
Courtesy of DAIMLERCHRYSLER CORP.
Install the clutch plate (4) onto the front of the A/C compressor (5).
Install the compressor shaft bolt (3). Tighten the bolt to 19 N.m (168 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 correct. Spin the pulley before performing a final check of the air gap.

NOTE: On models with the clutch plate recessed into the pulley, use a 90° wire gap gauge to measure the clutch air gap. On other models, use a blade type feeler gauge to measure the air gap.
With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly. The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024 in.). If the air gap is not between specifications, add or subtract shims as needed until the correct air gap is obtained.
CAUTION: Be certain that the compressor clutch field coil wire lead is routed so that it is not pinched between the A/C compressor and the field coil connector bracket.
Carefully route the compressor clutch field coil wire lead behind the connector bracket (2).
Install the compressor clutch field coil connector (1) onto the connector bracket.
If removed, position the A/C compressor to the engine and install the retaining bolts (Refer to HEATING & AIR CONDITIONING/PLUMBING/COMPRESSOR-A/C - INSTALLATION) .
Connect the engine wire harness to the compressor clutch field coil connector.
Install the accessory drive belt (Refer to COOLING/ACCESSORY DRIVE/BELTS-DRIVE - INSTALLATION) .
Reconnect the negative battery cable.