lock CHRYSLER VOYAGER 2004 Service Manual

WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
FRONT DOOR GLASS RUN WEATHERSTRIP
REMOVAL............................113
INSTALLATION........................113
FRONT DOOR OUTER BELT MOLDING
REMOVAL............................113
INSTALLATION........................113
FRONT DOOR WEATHERSTRIP
REMOVAL............................114INSTALLATION........................114
SLIDING DOOR WEATHERSTRIP
REMOVAL............................115
INSTALLATION........................115
FRONT DOOR INNER BELT MOLDING
REMOVAL............................115
INSTALLATION........................115
FRONT DOOR GLASS RUN
WEATHERSTRIP
REMOVAL
(1) Remove door frame closeout moldings.
(2) Pull weatherstrip from glass run channel at
rear of door frame, working from the bottom to the
top.
(3) Disengage clip attaching weatherstrip to door
frame.
(4) Pull weatherstrip from lip along top of door
frame (Fig. 1).
(5) Remove door trim panel.
(6) Remove door speaker, if equipped.
(7) Remove watershed as necessary to gain access
to screw attaching front lower corner of glass run
weatherstrip to inner door panel.
(8) Remove screw attaching glass run weatherstrip
to inner door panel.
(9) Remove inner belt weatherstrip.
(10) Pull weatherstrip from front glass run chan-
nel.
(11) Remove glass run weatherstrip from vehicle.
INSTALLATION
(1) Position glass run weatherstrip on vehicle (Fig.
1).
(2) Push weatherstrip into front glass run channel.
(3) Install screw attaching glass run weatherstrip
to inner door panel.
(4) Install inner belt weatherstrip.
(5) Install watershed.(6) Push weatherstrip groove onto lip along top of
door frame.
(7) Engage clip into slot in door frame.
(8) Push weatherstrip into channel at rear of door
frame, working from the top to bottom.
(9) Install door frame closeout moldings.
(10) Install door speaker, if equipped.
(11) Install door trim panel.
FRONT DOOR OUTER BELT
MOLDING
REMOVAL
(1) Remove the side view mirror. (Refer to 23 -
BODY/EXTERIOR/SIDE VIEW MIRROR -
REMOVAL)
(2) Remove door trim panel.
(3) Roll door glass down.
(4) Using a hook tool, disengage interlocking lip at
the base of the inward edge of the belt molding (Fig.
1).
(5) Remove belt molding from door.
INSTALLATION
(1) Place belt molding in position on door (Fig. 1).
NOTE: Make sure end of applique is against outer
belt.
(2) Engage interlocking lip at the base of the
inward edge of the belt molding on door panel.
(3) Install door trim panel.
RSWEATHERSTRIP/SEALS23 - 113

SUNROOF
TABLE OF CONTENTS
page page
SUNROOF
DESCRIPTION........................116
DIAGNOSIS AND TESTING - SUNROOF.....116
DRAIN TUBE
REMOVAL............................119
INSTALLATION........................120
GLASS PANEL
REMOVAL............................120
INSTALLATION........................120
ADJUSTMENTS
SUNROOF GLASS PANEL ADJUSTMENT . . 120
SUNROOF ASSEMBLY
REMOVAL............................120
INSTALLATION........................120
SUNSHADE
REMOVAL............................120INSTALLATION........................121
WIND DEFLECTOR
REMOVAL............................121
INSTALLATION........................121
WATER CHANNEL
REMOVAL............................121
INSTALLATION........................121
SUNROOF MOTOR
REMOVAL............................121
INSTALLATION........................121
ADJUSTMENTS
ADJUSTMENT.......................122
SUNROOF SWITCH
REMOVAL............................123
INSTALLATION........................123
SUNROOF
DESCRIPTION
WARNING: Keep fingers and other body parts out
of sunroof opening at all times.
The sun roof features consists of: (Fig. 1)
²Sun roof glass
²Sun roof sun shade
The sunroof power sliding glass panel and sun-
shade can be positioned anywhere along its travel,
rearward of glass panel front edge.
The sunroof is electrically operated from a switch
located in the overhead console. To operate the sun-
roof the ignition switch must be in the Accessory or
On/Run position. Both switchs are a rocker style
design that open or close the sunroof. When pressing
and releasing the open button once, the sunroof will
express open to the comfort stop and the wind deflec-
tor will raise. If the button is pressed a second time,
the sunroof will continue to open to full travel unless
the button is released, at which time it will stop in
that position. Pressing and holding the close button
will close the sunroof. If the close button is released
before the glass fully closes, the sunroof will stop in
that position. The vent switch operates in a similar
manor. The sunroof will also operate for up to fifteenminutes after the ignition key is turned off for cus-
tomer comfort and convenance while parking.
DIAGNOSIS AND TESTING - SUNROOF
Refer to Sunroof Diagnostic Chart for possible
causes. Before beginning sunroof diagnostics verify
that all other power accessories are in proper operat-
ing condition. If not, a common electrical problem
may exist. Refer to Wiring Diagrams, in this publica-
tion for circuit, splice and component descriptions.
Check the condition of the circuit protection (20 amp
circuit breaker in the Junction Block). Inspect all
wiring connector pins for proper engagement and
continuity. Check for battery voltage at the power
sunroof controller, refer to Wiring Diagrams, for cir-
cuit information. If battery voltage of more than 10
volts is detected at the controller, proceed with the
following tests (the controller will not operate at less
than 10 volts).
Before beginning diagnosis for wind noise or water
leaks, verify that the problem was not caused by
releasing the control switch before the sunroof was
fully closed. The sunroof module has a water-man-
agement system. If however, the sunroof glass is in a
partial closed position, high pressure water may be
forced beyond the water management system bound-
aries and onto the headlining.
23 - 116 SUNROOFRS

(6) Depress the spring feet clips on one side of the
sun shade.
(7) Remove sunshade.
INSTALLATION
(1) Place one side of the sunshade spring feet clips
into the top track U-frame.
(2) Depress the both releasing clips on the other
side to allow them to go into the top track U-frame.
(3) Move sunshade to the open position.
(4) Install water channel (Fig. 1).
(5) Verify that the sunshade move back and forth
properly.
(6) Cycle sunroof towards the closed position.
(7) Install glass panel (Refer to 23 - BODY/SUN-
ROOF/GLASS PANEL - INSTALLATION).
WIND DEFLECTOR
REMOVAL
(1) Fully open sunroof glass panel.
(2) Disconnect negative battery cable.
(3) Remove sunroof assembly (Refer to 23 - BODY/
SUNROOF/MODULE ASSEMBLY - REMOVAL).
(4) Depress the front deflector retaining tabs. (Fig.
2)
(5) Remove wind deflector.
INSTALLATION
(1) Place wind deflector arms in upward position
engage the wind deflector blade into the U-frame.
(2) Engage the retaining clips (Fig. 1).
(3) Verify wind deflector operation.
(4) Install the sun roof assembly (Refer to 23 -
BODY/SUNROOF/MODULE ASSEMBLY - INSTAL-
LATION).
WATER CHANNEL
REMOVAL
(1) Remove glass panel (Refer to 23 - BODY/SUN-
ROOF/GLASS PANEL - REMOVAL).
(2) Remove the retaining screws (Fig. 1).
(3) Carefully slide water channel forward to
release tabs from U-frame and remove from vehicle.
INSTALLATION
(1) Carefully place water channel onto U-frame
and slide it rearward to lock tabs (Fig. 1).
(2) Install the water channel attaching screws
(Fig. 1).
(3) Position glass panel on to mechanism lift arms.
(4) Start the glass attaching screws, and hand
tighten.
(5) Adjust sunroof glass (Refer to 23 - BODY/SUN-
ROOF/GLASS PANEL - ADJUSTMENTS).
(6) Verify sunroof operation and alignment.
SUNROOF MOTOR
REMOVAL
(1) Remove the sunroof (Refer to 23 - BODY/SUN-
ROOF/MODULE ASSEMBLY - REMOVAL).
(2) Remove the sunroof motor retaining bolts and
remove motor (Fig. 1).
INSTALLATION
CAUTION: THE SUNROOF MOTOR MUST BE TIMED
WITH THE SUNROOF ASSEMBLY. FAILURE TO DO
SO WILL RESULT IN IMPROPER SUNROOF OPERA-
TION AND POSSIBLE LEAKAGE OR DAMAGE TO
THE ASSEMBLY.
(1) Assure proper sunroof motor timing before
installation (Refer to 23 - BODY/SUNROOF/DRIVE
MOTOR - ADJUSTMENTS).
(2) Position the sunroof motor to the sunroof
assembly and install the retaining bolts (Fig. 1).
Tighten sunroof motor retaining bolts to 4.2Nm (40
lbs.in.).
Fig. 2 WIND DEFLECTOR
1 - Sun Roof
2 - Retaing Clip
3 - Sun Roof Assembly Trim
RSSUNROOF23 - 121
SUNSHADE (Continued)

(3) Connect the timed sunroof assembly to a
power source and assure proper operation before
installing the sunroof assembly into the vehicle.
ADJUSTMENTS
ADJUSTMENT
CAUTION: THE IS NO ADJUSTMENT AVAILABLE
FOR A NORMALLY OPERATING SUNROOF. THIS
PROCEDURE IS USE TO SET SUNROOF MOTOR TO
SUNROOF ASSEMBLY TIMING.
(1) Manually push the sunroof guide assembly to
the full forward position until it is locked into posi-
tion. This is verified by attempting to push the guide
assembly rearward. (Fig. 3)
NOTE: The guide rail will be raised above the
U-frame assembly when in the lock position.
(2) Remove the sunroof glass (Refer to 23 - BODY/
SUNROOF/GLASS PANEL - REMOVAL).
(3) Manually move the guide piviot inside the
guide rail cam slot until it is centered between the
etched timing marks on both rails. (Fig. 4)
(4) Verify that the white marking is visible in the
new motor window. If the mark is not visible, connecta power source to the motor and cycle the switch
until the motor is in the closed position (white mark
in window). (Fig. 5)
Fig. 3 SUNROOF GUIDE LOCK POSITION
1 - SUN SHADE
2-U-FRAME
3 - U- FRAME SLOT
4 - GUIDE RAIL
5 - GUIDE RAIL PIVIOT
6 - WIND DEFLECTOR
Fig. 4 SUNROOF GUIDE PIVOT
1 - TIMING MARKS
2 - GUIDE RAIL
3 - GUIDE RAIL PIVIOT
4 - U-FRAME
5 - WIND DEFLECTOR
Fig. 5 SUNROOF MOTOR
1 - SUNROOF MOTOR TIMING WINDOW
2 - SUNROOF MOTOR
23 - 122 SUNROOFRS
SUNROOF MOTOR (Continued)

HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - ENGINE COOLING
SYSTEM REQUIREMENTS...............1
DESCRIPTION - HEATER AND AIR
CONDITIONER........................1
DESCRIPTION - SINGLE ZONE...........2
DESCRIPTION - DUAL ZONE.............2
DESCRIPTION - MANUAL THREE ZONE.....2
DESCRIPTION - AUTOMATIC THREE ZONE . . 3
OPERATION
OPERATION - HEATER AND AIR
CONDITIONER........................4
OPERATION - SINGLE ZONE.............4
OPERATION - DUAL ZONE...............5
OPERATION - MANUAL THREE ZONE......5
OPERATION - THREE ZONE ATC..........5DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C COOL
DOWN TEST..........................6
DIAGNOSIS AND TESTING - A/C
PERFORMANCE TEST..................7
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE TEST.................10
SPECIFICATIONS
A/C SYSTEM.........................11
CONTROLS - FRONT.....................14
CONTROLS - REAR......................34
DISTRIBUTION - FRONT...................43
DISTRIBUTION - REAR....................56
PLUMBING - FRONT.....................64
PLUMBING - REAR......................97
CABIN HEATER........................112
HEATING & AIR
CONDITIONING
DESCRIPTION
DESCRIPTION - ENGINE COOLING SYSTEM
REQUIREMENTS
To maintain the performance level of the heating,
ventilation and air conditioning (HVAC) system, the
engine cooling system must be properly maintained.
The use of a bug screen is not recommended. Any
obstructions in front of the radiator or condenser will
reduce the performance of the air conditioning and
engine cooling systems.
The engine cooling system includes the radiator,
thermostat, radiator hoses and the engine coolant
pump. Refer to Cooling for more information before
opening or attempting any service to the engine cool-
ing system.
DESCRIPTION - HEATER AND AIR
CONDITIONER
A manually controlled single zone type heating-air
conditioning system, manually controlled dual zone
type heating-air conditioning system, manually con-
trolled three zone type heating-air conditioning sys-
tem or an automatic controlled three zone typeheating-air conditioning system is available on this
model.
All vehicles are equipped with a common heater,
ventilation and air conditioning (HVAC) housing (Fig.
1). The system combines air conditioning, heating,
and ventilating capabilities in a single unit housing
mounted within the passenger compartment under
the instrument panel. The HVAC housing includes:
²Blower motor
²Blower motor resistor block or power module
(depending on application)
²Heater core
²Evaporator coil
²Blend door and actuator
²Mode door and actuator
²Recirculation door and actuator
Based upon the system and mode selected, condi-
tioned air can exit the HVAC housing through one or
a combination of the three main housing outlets:
defrost, panel or floor. The defrost and panel outlets
are located on the top of the housing and the floor
outlet is located on the bottom of the housing. Once
the conditioned air exits the unit housing, it is fur-
ther directed through molded plastic ducts to the var-
ious outlets in the vehicle interior. These outlets and
their locations are as follows:
²Defroster Outlet- A single large defroster out-
let is located in the center of the instrument panel
top cover, near the base of the windshield.
²Side Window Demister Outlets- There are
two side window demister outlets, one is located at
RSHEATING & AIR CONDITIONING24-1

²FAN/MODE± The Fan and Mode knobs have
17 manual selectable positions. Manually changing
either of the rotary knobs for mode or fan speed set-
tings makes control of that blowe motor manual. If
only one is changed manually, the other remains
under automatic control. Pressing the HI-AUTO/LO-
AUTO rocker switch restores full automatic control.
²REAR CONTROL± When the Rear System
control knob is moved to the OFF position, there will
be a delay of approximately 1 second before the sys-
tem actually turns off. This delay is to prevent an
undesired blower dropout if the knob is moved
through OFF to the other selections.
²BLOWER DELAY TIMER± The word DELAY
is displayed at start-up to signify that the system is
waiting so that cold air will not be blowing. This tells
the operator that it is unnecessary to turn the sys-
tem off, raise the temperature setting or turn the fan
speed setting down to prevent cold air from blowing.
A countdown in minutes and seconds until the engine
is warm enough to begin delivering heat to the pas-
sengers alternates with the DELAY message at 25
second intervals. This countdown is based on actual
measurement of the rate of engine coolant tempera-
ture change. During the delay time, mix mode is
selected and the fan operates at a low speed to keep
the windshield fog free.
REAR CONTROL PANEL
Primary control of the rear compartment unit is in
the instrument panel center stack. The rear unit con-
trol knob there allows the driver to turn the rear
unit off, allow control by the intermediate seat occu-
pants by switching to the REAR position, or provide
fully automatic control based on the temperature set-
ting shown on the front control display.
²REAR CONTROL± Selecting automatic control
of the rear unit at the instrument panel, illuminates
a Locked Padlock in the rear control panel display.
Selecting REAR activates the rear control panel and
the Padlock then appears unlocked.
²FAN KNOB± The rear fan control has Off and
AUTO positions and a range of manual speed set-
tings that override the AUTO setting.
²MODE KNOB± The mode control allows inter-
mediate seat occupants to manually override the
automatic mode and select any balance of air flow
between overhead and floor outlets from full over-
head to full floor.
²SET TEMP± The rear set temp control will
operate identical to the front controls. If the front
control rear set temp button is pressed simulta-
neously with the rear control head, then the front
control head press events shall have priority, i.e. if
the front user presses Rear Set Temp down and therear user presses Set Temp up, then the rear set
temp will decrease.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C COOL DOWN
TEST
The heater-A/C control module can perform an A/C
cool down test, which is a test performed during the
manufacturing process to confirm that the air condi-
tioning system is performing satisfactorily. This test
can also provide a quick confirmation of air condi-
tioning system performance to the service technician.
If the test is completed satisfactorily, no further ser-
vice is required. If the test is failed, proceed to the
A/C Performance Test to confirm the A/C system is
operating properly, or use a DRBIIItscan tool to
diagnose the A/C system control and distribution sys-
tems. Refer to the appropriate diagnostic informa-
tion.
MANUAL TEMPERATURE CONTROL
The front blower speed and rear blower speed (if
equipped with rear HVAC) must be set to High and
the evaporator temperature sensor must be greater
than 13É C (55É F) or the test will fail immediately.
The test is activated by depressing the A/C and Rear
Wipe/Wash buttons simultaneously and holding them
depressed for no less than five seconds. The Rear
Wipe/Wash and A/C LEDs will blink on and off until
the test is complete. If the LEDs stop blinking before
two minutes, then the cool down test has been com-
pleted successfully. If the two minutes expire without
the expansion valve temperature reaching -6É C (20É
F) less than the outside air temperature, then the
cool down test has been failed and further A/C sys-
tem diagnosis is required. If the test is failed, the
LEDs will continue to blink until the vehicle has
been driven for greater than 1.6 km (8 miles).
AUTOMATIC TEMPERATURE CONTROL
The ambient air temperature in the room where
the vehicle will be tested must be a minimum of 21É
C (70ÉF) for this test. The test is activated by
depressing the A/C and PWR buttons simultaneously
and holding them depressed for no less than four sec-
onds. The snowflake icon and the DELAY text in the
ATC display will blink on and off alternately until
the test is complete. If the snowflake icon and the
DELAY text stop blinking before two minutes, then
the cool down test has been completed successfully. If
the two minutes expire without the evaporator tem-
perature reaching -6É C (20É F) less than the evapo-
rator initial temperature, then the cool down test has
been failed and further A/C system diagnosis is
24 - 6 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)

Description N´m Ft. Lbs. In. Lbs.
A/C Expansion Valve
Screws11 ± 9 7
A/C-Heater Control
Screws2±17
Blend Door Actuator
Screws2±17
Blower Motor Screws 2 ± 17
Blower Motor Power
Module Screws (ATC)2±17
Blower Motor Resistor
Block Screws (MTC)2±17
Center Bezel Outlet
Screws2±17
Distribution Housing
Screws2±17
Discharge Line to
Compressor Nut23 17 ±
Discharge Line to
Condenser Nut23 17 ±
Front Fascia Screws 6 ± 53
Front Fascia Grille Insert
Screws2±17
Heater Core Mounting
Plate Screws2±17
Heater Core Sealing Plate
Screws3±26
Hood Latch Screws 14 ± 123
HVAC Housing Bracket
Bolt3±26
HVAC Housing Mounting
Nuts7±62
HVAC Housing Mounting
Bolts4±35
Liquid Line to Condenser
Nut23 17 ±
Liquid Line to Receiver/
drier Bolt11 ± 9 7
Lower Air inlet Housing
Screws2±17
Mode Door Actuator
Screws2±17
Quarter Trim Panel
Attaching Bracket Screws2±17
Rear Blower Motor
Screws2±17
Rear Blower Motor Power
Module Screws (ATC)2±17
24 - 12 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)

Description N´m Ft. Lbs. In. Lbs.
Rear Blower Motor
Resistor Block Screws
(MTC)2±17
Rear Capture Plate Screw 2 ± 17
Rear Evaporator Line Seal
Plate to Rear Expansion
Valve Nut23 17 ±
Rear Expansion Valve
Bracket Nut23 17 ±
Rear Expansion Valve
Bracket Screws2±17
Rear Expansion Valve to
Rear Evaporator Screws11 ± 9 7
Rear Floor Heat Duct
Screws2±17
Rear HVAC Housing
Screws2±17
Rear HVAC Housing
Mounting Screws11 ± 9 7
Rear HVAC Housing Stud
Nuts9±80
Rear Mode Door Actuator
Screws2±17
Receiver/drier Bracket
Nuts10 ± 89
Recirculation Door
Actuator Screws2±17
Refrigerant Lines to
Expansion Valve Nut23 17 ±
Suction Line to
Compressor Nut23 17 ±
Cabin Heater Air Intake
Pipe Screws7±62
Cabin Heater M6 Bolts 7 ± 62
Cabin Heater M8 Bolts 23 17 ±
Cabin Heater Seat Hex
Nut60 44 ±
Underbody Liquid Line
Fitting23 17 ±
Underbody Refrigerant
Line Sealing Plate Screw23 17 ±
Underbody Suction Line
Fitting23 17 ±
Upper Air Inlet Housing
Screws2±17
RSHEATING & AIR CONDITIONING24-13
HEATING & AIR CONDITIONING (Continued)

CONTROLS - FRONT
TABLE OF CONTENTS
page page
A/C COMPRESSOR CLUTCH/COIL
DESCRIPTION.........................15
OPERATION...........................15
DIAGNOSIS AND TESTING - A/C
COMPRESSOR CLUTCH COIL...........15
REMOVAL.............................16
INSPECTION..........................17
INSTALLATION.........................17
A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................20
INSTALLATION.........................20
A/C HEATER CONTROL
DESCRIPTION.........................20
STANDARD PROCEDURE - A/C-HEATER
CONTROL CALIBRATION...............20
REMOVAL.............................21
INSTALLATION.........................21
A/C PRESSURE TRANSDUCER
DESCRIPTION.........................21
OPERATION...........................21
DIAGNOSIS AND TESTING - A/C PRESSURE
TRANSDUCER.......................22
REMOVAL.............................22
INSTALLATION.........................22
BLEND DOOR ACTUATOR
DESCRIPTION.........................23
OPERATION...........................23
REMOVAL.............................23
INSTALLATION.........................23
BLOWER MOTOR RELAY
DESCRIPTION.........................24
OPERATION...........................24
REMOVAL.............................25
INSTALLATION.........................25
BLOWER MOTOR RESISTOR BLOCK
DESCRIPTION.........................26OPERATION...........................26
DIAGNOSIS AND TESTING - BLOWER
MOTOR RESISTOR BLOCK..............26
REMOVAL.............................26
INSTALLATION.........................27
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION.........................27
OPERATION...........................28
REMOVAL
REMOVAL - AUTOMATIC TEMPERATURE
CONTROL (ATC)......................28
REMOVAL - MANUAL TEMPERATURE
CONTROL (MTC)......................29
INSTALLATION
INSTALLATION - AUTOMATIC
TEMPERATURE CONTROL (ATC).........29
INSTALLATION - MANUAL TEMPERATURE
CONTROL (MTC)......................29
INFRARED TEMPERATURE SENSOR
DESCRIPTION.........................29
OPERATION...........................29
MODE DOOR ACTUATOR
DESCRIPTION.........................30
OPERATION...........................30
REMOVAL.............................30
INSTALLATION.........................31
POWER MODULE - BLOWER MOTOR
DESCRIPTION.........................31
OPERATION...........................31
REMOVAL.............................31
INSTALLATION.........................32
RECIRCULATION DOOR ACTUATOR
DESCRIPTION.........................32
OPERATION...........................32
REMOVAL.............................33
INSTALLATION.........................33
24 - 14 CONTROLS - FRONTRS

ented and routed so that they are not pinched
between the compressor front cover and the clutch
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) Using snap ring pliers (Special Tool C-4574 or
equivalent), install the external snap ring that
secures the clutch coil to the front cover of the com-
pressor. The bevel side of the snap ring must face
outward and both snap ring eyelets must be oriented
to the right or the left of the clutch coil dowel pin
location on the compressor. Be certain that the snap
ring is fully and 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 compressor front
cover.
(3) Install and securely tighten the screw that
secures the clutch coil pigtail wire connector bracket
and ground clip to the top of the compressor housing.
(4) Install the pulley onto the front cover of the
compressor. If necessary, tap the pulley gently with a
block of wood placed on the pulley friction surface
(Fig. 6).
CAUTION: Do not mar the friction surfaces of the
pulley.NOTE: A new snap ring must be used to secure the
clutch pulley to the compressor. The bevel side of
the snap ring must face outward.
(5) Using snap ring pliers (Special Tool C-4574 or
equivalent), install the external snap ring (bevel side
facing outward) that secures the clutch pulley to the
front cover of the compressor. Be certain that the
snap ring is fully and properly seated in the groove.
(6) If the original clutch plate and clutch pulley
are to be reused, reinstall the original shim(s) on the
compressor shaft against the shoulder. If a new
clutch plate and/or clutch pulley are being used,
install a trial stack of shims 1.0 mm (0.040 in.) thick
on the compressor shaft against the shoulder.
(7) Install the clutch plate onto the compressor
shaft.
NOTE: The shims may compress after tightening
the shaft bolt. Check the air gap in four or more
places to verify the air gap is still correct. Spin the
pulley before performing a final check of the air
gap.
(8) With the clutch plate assembly tight against
the shim(s), measure the air gap between the clutch
plate and the pulley face with feeler gauges. The air
gap should be between 0.35 - 0.60 mm (0.014 - 0.024
in.). If the proper air gap is not obtained, add or sub-
tract shims as needed until the desired air gap is
obtained.
(9) Install the compressor shaft bolt. Tighten the
bolt to 17.5 N´m (155 in. lbs.).
(10) On models with the 2.4L and 2.5L engines,
loosely install the four bolts that secure the compres-
sor to the mounting bracket on the engine (2.4L), or
the cylinder block (2.5L). Tighten the bolts to 28 N´m
(21 ft. lbs.).
(11) On models with the 3.3L and 3.8L engines,
loosely install the two bolts and two nuts that secure
the compressor to the engine. Tighten each of the fas-
teners to 54 N´m (40 ft. lbs.) using the following
sequence:
²The upper nut at the front of the compressor.
²The lower nut at the front of the compressor.
²The upper bolt at the rear of the compressor.
²The lower bolt at the rear of the compressor.
(12) On models with the 3.3L and 3.8L engines,
engage the retainer on the engine wire harness com-
pressor clutch coil take out with the bracket on the
top of the compressor.
(13) Reconnect the engine wire harness connector
for the compressor clutch coil to the coil pigtail wire
connector on the top of the compressor.
(14) Reinstall the serpentine accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - 2.4L - INSTALLATION) or (Refer to 7 -
Fig. 6 Install Clutch Pulley
1 - PULLEY ASSEMBLY
2 - WOOD BLOCK
24 - 18 CONTROLS - FRONTRS
A/C COMPRESSOR CLUTCH/COIL (Continued)