Grand Caravan FWD V6-3.3L VIN 3 Flex Fuel (2002)
Fig.16 Install Clutch Pulley
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.
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.
8. Install and tighten the compressor shaft nut. If necessary, a band-type oil filter wrench or a strap wrench can be placed around the clutch plate to
aid in bolt tightening. Tighten the bolt to 17.5 Nm (155 in. lbs.).
9. If a new clutch plate and/or clutch pulley are being installed, the air gap between the clutch plate and clutch pulley must be checked.
10. On models with the 2.4L engine only loosely install the four screws that secure the compressor to the mounting bracket on the engine. Tighten the
screws to 28 Nm (21 ft. lbs.).
11. On models with the 3.3L and 3.8L engines only, loosely install the three screws and one nut that secure the compressor to the engine. Tighten each
of the fasteners using the following sequence to 54 Nm (40 ft. lbs.).
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The upper screw at the rear of the compressor.
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The lower screw at the rear of the compressor.
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The lower screw at the front of the compressor.
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The upper nut at the front of the compressor.
12. On models with the 3.3L and 3.8L engines only, engage the retainer on the engine wire harness compressor 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 onto the front of the engine.
15. Lower the vehicle.
16. Reconnect the battery negative cable.
17. If a new clutch plate and/or clutch pulley are being installed, the new clutch components must be burnished.
