HVAC Systems - Compressor Servicing: Removal & Installation Dodge Stratus I

Removal

Remove compressor shaft bolt. Tighten a 10-mm bolt into clutch hub bolt hole to remove clutch hub. Remove shims and snap ring. Remove rotor and pulley assembly. Remove snap ring, and disconnect clutch coil lead. Remove clutch coil.

Installation

1. Install clutch coil so pin in back of coil aligns with hole in front housing. Install snap ring. Install rotor and pulley assembly. Install snap ring and shims. Install clutch hub.
2. Install dial indicator to measure clutch hub air gap. Apply battery voltage to energize clutch coil. Proper air gap clearance is .014-.026" (.36-.66 mm). Adjust shim thickness to obtain correct clearance. Install compressor shaft bolt. Tighten compressor shaft bolt to 10 ft. lbs. (14 N.m).

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure amount drained. Remove clutch hub, shims, rotor and pulley assembly, and clutch coil. (Scheme 1)
2. Remove front housing. Remove felt holder and felt washer from front housing. Remove shaft seal snap ring. Position front housing (nose up) on cardboard placed on a flat surface. Using brass drift, press shaft seal from front housing.

1. Lubricate new shaft seal with refrigerant oil. DO NOT touch sealing surfaces. Using a 21-mm socket, press seal into front housing, and install snap ring. Ensure shaft seal "O" ring side is facing the front housing (away from compressor). Using a 14-mm deep socket, install felt washer and dust holder.
2. Lubricate Shaft Seal Protector (J-34614) and front housing "O" ring with refrigerant oil. Install shaft seal protector on compressor shaft. Install a new front housing "O" ring on compressor assembly.
3. Install front housing on compressor assembly. Ensure dowel pins are aligned. Use care when guiding shaft seal protector through seal opening. Remove shaft seal protector.
4. Install through-bolts and new brass washers. Diagonally tighten bolts to 19 ft. lbs. (26 N.m). Using INCH-lb. torque wrench, check compressor shaft rotating torque. Rotating torque should be 43 INCH lbs. (5 N.m) or less.
5. Using new refrigerant oil, add same amount of oil to compressor as was drained from it. Install compressor. Evacuate and charge system. Perform leak test.

Scheme 1

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure amount drained.
2. Using a spanner wrench, hold clutch and remove compressor shaft nut. Using a steering wheel puller, remove clutch plate. Remove internal bearing dust cover and internal bearing snap ring. Remove key from compressor shaft.
3. Remove external front housing snap ring. Install jaws of puller in snap ring groove on pulley. Install puller plate on jaws. Thread 2 bolts through puller plate into jaws and finger tighten. Tighten pulley center bolt and remove pulley from compressor. Remove clutch coil snap ring and clutch coil.

1. Install clutch coil and clutch coil snap ring on compressor. Support compressor on rear mounting ears.
2. Using hammer, Handle (J-29886) and Driver (J-38467), install pulley assembly. Ensure driver rests on inner race of bearing when installing pulley assembly. Install external snap ring.
3. Install original shims. Use a hammer and Shaft Protector (J-29640) to install clutch plate on compressor shaft. Tighten compressor shaft nut to 10 ft. lbs. (14 N.m).
4. Using feeler gauge, measure clearance between clutch plate and pulley assembly in several areas. Clearance should be .016-.031" (.41-.79 mm). If clearance is not within specification, adjust shim thickness to obtain correct clearance.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure amount drained.
2. Remove pulley assembly. Using Spanner (MB991367) and Pins (MB991386), remove shaft nut. Remove clutch plate, snap ring and rotor assembly. Remove snap ring and clutch coil. (Scheme 2)

1. Install clutch coil. Ensure projection on back of clutch coil is aligned with pin hole in compressor body. Install snap ring so that tapered surface is facing outward.
2. Install rotor assembly and snap ring. Align match mark of clutch plate with match mark of compressor shaft spline and install clutch plate. Using spanner and pins, install shaft nut.
3. Using a feeler gauge, check clearance between clutch plate and rotor assembly at more than one place. Proper clearance should be .016-.026" (.41-.66 mm). If clearance is not within specification, add or remove shims to obtain correct clearance. Install pulley assembly.
4. Using new refrigerant oil, add same amount of oil to compressor as was drained from it. Install compressor. Evacuate and charge system. Perform leak test.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure amount drained.
2. Remove pulley assembly. Using Spanner (MB991367) and Pins (MB991386), remove shaft nut. Remove clutch plate, snap ring and rotor assembly. Remove snap ring and clutch coil. (Scheme 2)
3. Remove the bearing cover and retainer. Using Bearing Puller (MB991456), remove front shaft bearing. Remove snap ring.
4. Insert Lip Seal Installer/Remover (MB991458), into neck of compressor and catch lip seal tab. Remove lip seal from compressor by pulling it straight out.

1. Install Lip Seal Installer Guide (MB991459) over compressor shaft. Apply refrigerant oil to installer guide and to lip seal. Slide lip seal over guide and use lip seal installer/remover to install lip seal. Install snap ring. (Scheme 2)
2. Position compressor on a wooden support. Using a hammer and a 21-mm socket, install bearing into compressor. Install shims. Install clutch coil. Ensure projection on back of clutch coil is aligned with pin hole in compressor body. Install snap ring so that tapered surface is facing outward.
3. Install rotor assembly and snap ring. Align match mark of clutch plate with match mark of compressor shaft spline and install clutch plate. Using spanner and pins, install shaft nut.
4. Using a feeler gauge, check clearance between clutch plate and rotor assembly at more than one place. Proper clearance should be.016-.026" (.41-.66 mm). If clearance is not within specification, add or remove shims to obtain correct clearance. Install pulley assembly.
5. Using new refrigerant oil, add same amount of oil to compressor as was drained from it. Install compressor. Evacuate and charge system. Perform leak test.

Scheme 2

1. Without discharging A/C system, remove compressor from mount. Install two 6-mm bolts in holes of clutch plate. Use 6-mm bolts and 2 box-end wrenches to hold clutch plate while removing nut from end of compressor shaft.
2. Remove clutch plate and shims. Using a plastic hammer, tap clutch plate from compressor (if necessary). DO NOT pry between clutch plate and pulley to remove clutch plate.
3. Remove pulley assembly snap ring. Remove pulley assembly. Disconnect clutch coil lead. Scribe marks on clutch coil and compressor for installation reference. Remove snap ring and clutch coil.

Note. Rotor/pulley assembly and clutch plate are a matched pair and should be replaced together.

1. Install clutch coil on compressor so locating pin engages locating indentation. Install snap ring with beveled side away from compressor. Secure clutch coil lead to compressor front cover and connect lead to thermal limiter switch.
2. Install pulley assembly. Install snap ring with beveled side away from compressor. If reusing original clutch plate and pulley, old shims can be used.
3. If new components are used, install several shims so shim pack thickness is .10" (2.5 mm). Align machined match marks and install clutch plate and hold it tightly against shims.
4. Measure air gap between clutch plate and pulley surface. Proper clearance is .013-.025" (.33-.64 mm). Adjust shim thickness to obtain correct clearance. Tighten compressor shaft nut to 13 ft. lbs. (18 N.m).
5. Once compressor shaft nut is tightened, recheck clearance between clutch plate and pulley surface in 4 places. Readjust clearance if necessary. Install compressor.
6. Evacuate and charge system. Break-in compressor clutch assembly by engaging and disengaging clutch 20 times with engine at 1500-2000 RPM. Perform leak test.