Dodge Durango (DN). Manual — part 195

INSTALLATION

NOTE: If

a

replacement

compressor

is

being

installed, be certain to check the refrigerant oil
level. See Refrigerant Oil Level in the Service Pro-
cedures section of this group. Use only refrigerant
oil of the type recommended for the compressor in
the vehicle.

(1) Install the compressor to the mounting bracket.

Tighten the four mounting screws to 27 N·m (20 ft.
lbs.).

(2) Remove the tape or plugs from all of the

opened refrigerant line fittings. Install the suction
and discharge line manifold to the compressor. See
Suction and Discharge Line in the Removal and
Installation section of this group for the procedures.

(3) Install the serpentine drive belt. Refer to

Group 7 - Cooling System for the procedures.

(4) Plug in the compressor clutch coil wire harness

connector.

(5) Connect the battery negative cable.
(6) Evacuate the refrigerant system. See Refriger-

ant System Evacuate in the Service Procedures sec-
tion of this group.

(7) Charge the refrigerant system. See Refrigerant

System Charge in the Service Procedures section of
this group.

COMPRESSOR CLUTCH

The refrigerant system can remain fully-charged

during compressor clutch, pulley, or coil replacement.
The compressor clutch can be serviced in the vehicle.

REMOVAL

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the serpentine drive belt. Refer to

Group 7 - Cooling System for the procedures.

(3) Unplug the compressor clutch coil wire harness

connector.

(4) Insert the two pins of the spanner wrench

(Special Tool 6462 in Kit 6460) into the holes of the
clutch plate. Hold the clutch plate stationary and
remove the hex nut (Fig. 26).

(5) Remove the clutch plate and the clutch shims.
(6) Remove the external front housing snap ring

with snap ring pliers (Fig. 27).

(7) Install the lip of the rotor puller (Special Tool

C-6141-1 in Kit 6460) into the snap ring groove
exposed in Step 6, and install the shaft protector
(Special Tool C-6141-2 in Kit 6460) (Fig. 28).

(8) Install the puller through-bolts (Special Tool

C-6461) through the puller flange and into the jaws
of the rotor puller and tighten (Fig. 29). Turn the

puller center bolt clockwise until the rotor pulley is
free.

(9) Remove the screw and retainer from the clutch

coil lead wire harness on the compressor front hous-
ing (Fig. 30).

(10) Remove the snap ring from the compressor

hub and remove the clutch field coil (Fig. 31). Slide
the clutch field coil off of the compressor hub.

Fig. 26 Clutch Nut Remove

1 – FRONT PLATE SPANNER

Fig. 27 External Snap Ring Remove

1 – EXTERNAL SNAP RING

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HEATING AND AIR CONDITIONING

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REMOVAL AND INSTALLATION (Continued)

INSPECTION

Examine the friction surfaces of the clutch pulley

and the front plate for wear. The pulley and front

plate should be replaced if there is excessive wear or
scoring.

If the friction surfaces are oily, inspect the shaft

and nose area of the compressor for oil. Remove the
felt from the front cover. If the felt is saturated with
oil, the shaft seal is leaking and the compressor must
be replaced.

Fig. 28 Shaft Protector and Puller

1 – PULLER SHAFT PROTECTOR
2 – JAWS

Fig. 29 Install Puller Plate

1 – BOLT
2 – PULLER PLATE AND BOLT
3 – BOLT
4 – JAWS

Fig. 30 Clutch Coil Lead Wire Harness

1 – CLIP

Fig. 31 Clutch Field Coil Snap Ring Remove

1 – FIELD COIL
2 – SNAP RING

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HEATING AND AIR CONDITIONING

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REMOVAL AND INSTALLATION (Continued)

Check the clutch pulley bearing for roughness or

excessive leakage of grease. Replace the bearing, if
required.

INSTALLATION

(1) Install the clutch field coil and snap ring.
(2) Install the clutch coil lead wire harness retain-

ing clip on the compressor front housing and tighten
the retaining screw.

(3) Align the rotor assembly squarely on the front

compressor housing hub.

(4) Thread the handle (Special Tool 6464 in Kit

6460) into the driver (Special Tool 6143 in Kit 6460)
(Fig. 32).

(5) Place the driver tool assembly into the bearing

cavity on the rotor. Make certain the outer edge of
the tool rests firmly on the rotor bearing inner race
(Fig. 33).

(6) Tap the end of the driver while guiding the

rotor to prevent binding. Tap until the rotor bottoms
against the compressor front housing hub. Listen for
a distinct change of sound during the tapping pro-
cess, to indicate the bottoming of the rotor.

(7) Install the external front rotor snap ring with

snap ring pliers. The bevel side of the snap ring must
be facing outward. Press the snap ring to make sure
it is properly seated in the groove.

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 front housing of the
compressor.

(8) Install the original clutch shims on the com-

pressor shaft.

(9) Install the clutch plate. Use the shaft protector

(Special Tool 6141-2 in Kit 6460) to install the clutch
plate on the compressor shaft (Fig. 34). Tap the
clutch plate over the compressor shaft until it has
bottomed against the clutch shims. Listen for a dis-
tinct change of sound during the tapping process, to
indicate the bottoming of the clutch plate.

(10) Replace the compressor shaft hex nut. Tighten

the nut to 14.4 N·m (10.5 ft. lbs.).

(11) Check the clutch air gap with a feeler gauge

(Fig. 35). If the air gap does not meet the specifica-

Fig. 32 Rotor Installer Set

Fig. 33 Rotor Install

Fig. 34 Clutch Plate Install

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REMOVAL AND INSTALLATION (Continued)

tion, add or subtract shims as required. The air gap
specification is 0.41 to 0.79 millimeter (0.016 to 0.031
inch). If the air gap is not consistent around the cir-
cumference of the clutch, lightly pry up at the mini-
mum variations. Lightly tap down at the points of
maximum variation.

NOTE: The air gap is determined by the spacer
shims. When installing an original, or a new clutch
assembly, try the original shims first. When install-
ing a new clutch onto a compressor that previously
did not have a clutch, use 1.0, 0.50, and 0.13 milli-
meter (0.040, 0.020, and 0.005 inch) shims from the
clutch hardware package that is provided with the
new clutch.

(12) Reverse the remaining removal procedures to

complete the installation.

CLUTCH BREAK-IN

After a new compressor clutch has been installed,

cycle the compressor clutch approximately twenty
times (five seconds on, then five seconds off). During
this procedure, set the heater-A/C control to the
recirculation mode (Max-A/C), the blower motor
switch to the highest speed position, and the engine
speed at 1500 to 2000 rpm. This procedure (burnish-
ing) will seat the opposing friction surfaces and pro-
vide a higher compressor clutch torque capability.

COMPRESSOR CLUTCH RELAY

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the cover from the Power Distribution

Center (PDC) (Fig. 36).

(3) Refer to the label on the PDC for compressor

clutch relay identification and location.

(4) Unplug the compressor clutch relay from the

PDC.

(5) Install the compressor clutch relay by aligning

the relay terminals with the cavities in the PDC and
pushing the relay firmly into place.

(6) Install the PDC cover.
(7) Connect the battery negative cable.
(8) Test the relay operation.

CONDENSER

WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE GENERAL INFORMATION SECTION
NEAR THE FRONT OF THIS GROUP BEFORE PER-
FORMING THE FOLLOWING OPERATION.

CAUTION: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
condenser and radiator. The air seals must be rein-
stalled in their proper locations in order for the air
conditioning and engine cooling systems to per-
form as designed.

REMOVAL

(1) Disconnect and isolate the battery negative

cable.

(2) Recover the refrigerant from the refrigerant

system. See Refrigerant Recovery in the Service Pro-
cedures section of this group.

Fig. 35 Check Clutch Air Gap

1 – FEELER GAUGE

Fig. 36 Power Distribution Center

1 – CLIP
2 – BATTERY
3 – TRAY
4 – NEGATIVE CABLE
5 – POSITIVE CABLE
6 – CLIP
7 – FENDER INNER SHIELD
8 – POWER DISTRIBUTION CENTER

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HEATING AND AIR CONDITIONING

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REMOVAL AND INSTALLATION (Continued)