Clutch Assembly: Installation
- Install clutch coil so pin in back of coil aligns with hole in front compressor housing. Ensure wiring harness is routed so wires are not pinched. Connect clutch coil and diode lead. Install NEW snap ring, with bevel side facing outward. Ensure snap ring is properly seated in groove.
- Install rotor and pulley assembly. Install shims and snap ring. On Caravan, Town & Country and Voyager, if a new clutch assembly is being installed, use a shim stack that is 0.040" (1.0 mm) thick. On Neon and PT Cruiser, if a new clutch assembly is being installed, use a shim stack that is 0.10" (2.5 mm) thick. Install clutch hub.
- Install dial indicator at front of clutch hub to measure clutch hub air gap. Using battery voltage, energize clutch coil. On Caravan, Town & Country and Voyager, proper air gap is 0.020-0.035" (0.51-0.89 mm). On Neon and PT Cruiser, proper air gap is 0.014-0.026" (0.35-0.65 mm). On all models, add or remove shims to obtain correct air gap. Install compressor shaft bolt. Tighten compressor shaft bolt to 11-15 ft. lbs. (15-20 N.m).
- On Caravan, Town & Country and Voyager with 2.4L engine, and Neon and PT Cruiser, loosely install all compressor mounting bolts and then tighten to 21 ft. lbs. (28 N.m). On Caravan, Town & Country and Voyager with 3.3L and 3.8L engines, loosely install all compressor mounting bolts and nut, and then tighten to 40 ft. lbs. (54 N.m) in order. Tighten compressor upper rear bolt, lower rear bolt, lower front bolt and then upper front nut.
- On all models, after completing compressor clutch installation, start engine. Set A/C-heater control to recirculated air mode and high blower motor speed. Set engine speed to 1500-2000 RPM. Cycle compressor on for 5 seconds and off for 5 seconds, about 20 times to burnish or break-in clutch friction surfaces.
Courtesy of CHRYSLER CORP.