Dodge Intrepid Service Manual page 948

LH
A/C COMPRESSOR CLUTCH (Continued)
INSTALLATION
(1) Align pin in back of field coil with hole in com-
pressor end housing, and position field coil into place.
Make sure that lead wires are properly routed, and
fasten the diode and coil wire bracket with retaining
screw.
(2) Install field coil retaining snap ring with Snap
Ring Pliers (C- 4574). Press snap ring to make sure
it is properly seated in the groove.
NOTE: The bevel side of the snap ring must be out-
ward. Also both eyelets must be to the right or left
of the pin on the compressor.
CAUTION: If snap ring is not fully seated it will
vibrate out, resulting in a clutch failure and severe
damage to the front face of the compressor.
Do not mar the pulley frictional surface.
(3) Install pulley assembly to compressor. If neces-
sary, tap gently with a block of wood on the friction
surface (Fig. 5).
(4) Install pulley assembly retaining snap ring
(bevel side outward) with Snap Ring Pliers (C-4574).
Press the snap ring to make sure it is properly
seated in the groove.
NOTE: The bevel side of the snap ring must be fac-
ing outward.
(5) If the original front plate assembly and pulley
assembly are to be reused, the old shim(s) can be
used. If not, place a trial stack of shims, 2.54 mm
(0.10 in.) thick, on the shaft against the shoulder.
(6) Install front plate assembly onto shaft.
(7) If installing a new front plate and/or pulley
assembly, the gap between front plate and pulley face
must be checked. Use the following procedure:
(a) Attach a dial indicator to front plate so that
movement of the plate can be measured.
(b) With the dial indicator zeroed on the front
plate, energize the clutch and record the amount of
movement.
(c) The readings should be 0.35 to 0.65 mm
(0.014 to 0.026 in.). If proper reading is not
obtained, add or subtract shims until desired read-
ing is obtained.
(8) Install compressor shaft bolt. Tighten to 17.5 ±
2 N·m (155 ± 20 in. lbs.).
NOTE: Shims may compress after tightening shaft
nut. Check air gap in four or more places to verify if
air gap is still correct. Spin pulley for final check.
Fig. 5 INSTALLING PULLEY ASSEMBLY
1 - PULLEY ASSEMBLY
2 - WOOD BLOCK
(9) Install the accessory drive belts (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION) or (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - INSTALLATION).
A/C COMPRESSOR CLUTCH
RELAY
DESCRIPTION
The compressor clutch relay is located in the Power
Distribution Center (PDC) in the engine compart-
ment. Refer to the PDC label for relay identification
and location.
OPERATION
The a/c compressor clutch relay is a electromechan-
ical device that switches battery current to the a/c
compressor clutch coil when the Powertrain Control
Module (PCM) grounds the coil side of the relay. The
PCM responds to inputs from the a/c heater control
(Manual Temperature Control, or Automatic Temper-
ature Control) , the Body Control Module (BCM), and
the a/c pressure transducer.
The compressor clutch relay cannot be repaired
and, if faulty or damaged, it must be replaced.
CONTROLS 24 - 11