2.4L NA/2.7L Engines

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.

Align the A/C clutch field coil squarely onto the A/C compressor housing front hub.
NOTE: Position the A/C clutch coil so that the coil positioning tab and the wire harness connector is oriented in the correct direction.
Install the clutch field coil onto the compressor with the compressor field coil installer (Special Tool 9352 in Kit 9349), compressor field coil installer spacer (Special Tool 9353 in Kit 9349) and a two jaw puller. See Fig 1.

Install the screw that secures the clutch coil wire harness connector to the compressor housing. Tighten the screw to 2 N.m (17 in. lbs.).

Fig 1: Clutch Field Coil

Courtesy of DAIMLERCHRYSLER CORP.

1 - TWO JAW PULLER

2 - FIELD COIL INSTALLER AND SPACER

3 - WIRE CONNECTOR

4 - CLUTCH FIELD COIL

Align the pulley and bearing assembly squarely onto the compressor front housing hub.
NOTE: A distinct change of sound during the clutch pulley tapping process indicates that the pulley and bearing assembly has bottomed out against the compressor housing.
Install the pulley and bearing assembly onto the compressor housing front hub with the clutch pulley installer (Special Tool 9355 in Kit 9349). See Fig 2. Tap the installer with a hammer until the pulley and bearing assembly has bottomed against the compressor housing.

Fig 2: Clutch Pulley Installer
Courtesy of DAIMLERCHRYSLER CORP.

1 - CLUTCH PULLEY INSTALLER

2 - PULLEY AND BEARING ASSEMBLY

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.

NOTE: Install the snap ring with the beveled side of the snap ring facing outward.
Install the snap ring that secures the pulley and bearing assembly to the compressor. Press the snap ring to make sure it is properly seated in the groove.
Verify that there is adequate clearance between the clutch field coil wire and the clutch pulley.
NOTE: When installing an original, or a new clutch assembly, try the original shims first. When installing a clutch onto a compressor that previously did not have a clutch, use 1.0, 0.50, and 0.13 millimeter (0.040, 0.020, and 0.005 inch) shims from the clutch hardware package that is provided with the new clutch.
Install the clutch shims onto the compressor shaft.
Install the clutch plate and bolt with the compressor clutch holding fixture (Special Tool 9351 in Kit 9349). See Fig 3. Hold the clutch plate stationary with the holding fixture and install the clutch bolt. Tighten the bolt to 13 N.m (115 in. lbs.).

Fig 3: A/C Clutch Bolt
Courtesy of DAIMLERCHRYSLER CORP.

1 - COMPRESSOR CLUTCH HOLDING FIXTURE

2 - CLUTCH BOLT
Check the clutch air gap with a feeler gauge. See Fig 4. If the air gap does not meet the specification, add or subtract shims as required. The air gap specification is 0.35 to 0.75 millimeter (0.014 to 0.030 inch).

Fig 4: Clutch Air Gap
Courtesy of DAIMLERCHRYSLER CORP.

1 - FEELER GAUGE
Position the A/C compressor onto the mounting bracket.
Install the bolts that secure the A/C compressor to the mounting bracket. Tighten the bolts to 28 N.m (20 ft. lbs.).
Connect the wire harness to the compressor clutch field coil connector.
Lower the vehicle.
Install the accessory drive belt (Refer to INSTALLATION ).
Reconnect the negative battery cable.
Perform the Clutch Break-in Procedure (Refer to HEATING & AIR CONDITIONING/CONTROLS/A/C COMPRESSOR CLUTCH - STANDARD PROCEDURE) .