Dodge Sprinter 2006 Manual page 2043

VA
Fig. 5 Clutch Coil Snap Ring
1 - SNAP RING PLIERS
2 - CLUTCH COIL
3 - SNAP RING
4 - COMPRESSOR
INSPECTION
Com pr essor clu t ch com pon en t s sh ou ld a lwa ys be
in spect ed closely befor e t h ey a r e r ein st a lled. Th e
clu t ch pla t e a n d clu t ch pu lley a r e m a t ed a t t h e fa c-
t or y u sin g a bu r n ish in g oper a t ion . No a t t em pt sh ou ld
be m a de t o sepa r a t ely r epla ce t h e com pr essor clu t ch
pu lley or clu t ch pla t e. Th e clu t ch coil m a y be ser viced
sepa r a t ely.
(1) E xa m in e t h e fr ict ion su r fa ces of t h e clu t ch pu l-
ley a n d t h e clu t ch pla t e for wea r. Th e clu t ch pu lley
a n d clu t ch pla t e sh ou ld be r epla ced if t h er e is exces-
sive wea r or scor in g.
(2) E xa m in e t h e fr ict ion su r fa ces of t h e clu t ch pu l-
ley a n d t h e clu t ch pla t e for oil con t a m in a t ion . If t h e
fr ict ion su r fa ces a r e oily, t h e clu t ch pu lley a n d clu t ch
pla t e sh ou ld be r epla ced. Also in spect t h e sh a ft a n d
n ose a r ea of t h e com pr essor for oil. Rem ove t h e felt
pa ckin g fr om a r ou n d t h e com pr essor sh a ft in t h e
com pr essor fr on t cover. If t h e felt is sa t u r a t ed wit h
oil, t h e com pr essor fr on t sh a ft sea l is lea kin g a n d t h e
com pr essor will a lso h a ve t o be r epla ced.
(3) Ch eck t h e clu t ch pu lley bea r in g for r ou gh n ess
or excessive lea ka ge of gr ea se. Repla ce t h e clu t ch
pu lley a n d clu t ch pla t e if t h e bea r in g is fa u lt y.
INSTALLA TION
(1) Align t h e dowel pin on t h e ba ck of t h e clu t ch
field coil wit h t h e h ole in t h e com pr essor fr on t cover,
a n d posit ion t h e clu t ch coil on t o t h e com pr essor. Be
cer t a in t h a t t h e clu ch coil wir e h a r n ess lea ds a r e
pr oper ly or ien t ed a n d r ou t ed so t h a t t h ey a r e n ot
pin ch ed bet ween t h e com pr essor fr on t cover a n d t h e
clu t ch 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) Usin g sn a p r in g plier s (Specia l Tool C-4574 or
equ iva len t ), in st a ll t h e ext er n a l sn a p r in g t h a t
secu r es t h e clu t ch coil t o t h e fr on t cover of t h e com -
pr essor. Th e bevel side of t h e sn a p r in g m u st be fa c-
in g ou t wa r d a n d bot h sn a p r in g eyelet s m u st be
or ien t ed t o t h e r igh t or left of t h e clu t ch coil dowel
pin on t h e com pr essor. Be cer t a in t h a t t h e sn a p r in g
is fu lly a n d pr oper ly sea t ed in t h e gr oove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the compressor front
cover.
(3) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e
clu t ch coil wir e h a r n ess con n ect or br a cket a n d
gr ou n d clip t o t h e t op of t h e com pr essor h ou sin g.
(4) In st a ll t h e pu lley on t o t h e fr on t of t h e com pr es-
sor. If n ecessa r y, pla ce a block of wood on t h e fr ict ion
su r fa ce a n d t a p gen t ly wit h a h a m m er (F ig. 6).
CAUTION: Do not mar the friction surfaces of the
pulley.
Fig. 6 Pulley Assembly Install
1 - PULLEY ASSEMBLY
2 - WOOD BLOCK
(5) Usin g sn a p r in g plier s (Specia l Tool C-4574 or
equ iva len t ), in st a ll t h e ext er n a l sn a p r in g (bevel side
fa cin g ou t wa r d) t h a t secu r es t h e clu t ch pu lley t o t h e
CONTROLS-FRONT 24 - 11