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
DN HEATING AND AIR CONDITIONING 24 - 41
REMOVAL AND INSTALLATION (Continued)
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