Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 133
(5) Add system capacity minus the capacity of com-
ponents that have not been replaced (refer to the
Refrigerant Oil Capacity Chart), through suction port
on compressor.
(6) Install compressor, connect refrigerant lines,
evacuate, and charge refrigerant system.
VARIABLE DISPLACEMENT COMPRESSOR SERVICE PROCEDURES
INDEX
page
page
Compressor Clutch/Coil Assembly
. . . . . . . . . . . . 27
Compressor Front Shaft Seal
. . . . . . . . . . . . . . . . 28
Compressor High Pressure Cut-Out Switch
. . . . . . 30
Compressor High Pressure Relief Valve
. . . . . . . . 31
Compressor Main or Sub Control Valves
. . . . . . . . 31
Compressor Removal and Installation
. . . . . . . . . . 27
COMPRESSOR REMOVAL AND INSTALLATION
The A/C compressor may be removed and positioned
without discharging the refrigerant system. Discharg-
ing is not necessary if removing the A/C compressor
clutch/coil assembly, engine, cylinder head, or alterna-
tor.
WARNING: REFRIGERANT PRESSURES REMAIN
HIGH EVEN THOUGH THE ENGINE MAY BE TURNED
OFF. BEFORE REMOVING A FULLY CHARGED COM-
PRESSOR, REVIEW THE SAFETY PRECAUTIONS
AND WARNINGS SECTION IN THIS GROUP. DO NOT
TWIST OR KINK THE REFRIGERANT LINES WHEN
REMOVING A FULLY CHARGED COMPRESSOR.
SAFETY GLASSES MUST BE WORN.
If the A/C compressor refrigerant lines must be
removed in order to remove compressor. Refer to Dis-
charging Refrigerant System in the Refrigerant Ser-
vice Procedures section before proceeding with the
following steps.
(1) Disconnect NEGATIVE battery cable.
(2) Loosen and remove drive belts (Refer to Group 7,
Cooling System) and disconnect compressor clutch
wire lead.
(3) Remove refrigerant lines from compressor (if
necessary).
(4) Remove compressor attaching nuts and bolts
(Fig. 1 and 2).
(5) Remove compressor. If refrigerant lines were not
removed, lift compressor/clutch assembly and tie it to a
suitable component.
To install, Reverse the preceding operation.
COMPRESSOR CLUTCH/COIL ASSEMBLY
REMOVAL AND INSTALLATION
Compressor assembly must be removed from mount-
ing. Although, refrigerant discharge is not necessary.
Fig. 1 A/C Compressor Removal and
Installation—3.3L Engines
Fig. 2 A/C Compressor Removal and
Installation—3.0 L Engine
.
HEATING AND AIR CONDITIONING
24 - 27
3.0 L ENGINE
Remove the front lower splash shield and front
engine mount through-bolt. Allow the engine to swing
down to provide access to the front of the compressor.
3.3 L ENGINE
Remove the coolant recovery bottle to provide access
the front of the compressor.
(1) Remove clutch retaining center nut by using
CLUTCH PLATE HOLDER (6355) (Fig. 3).
(2) Using a Clutch Plate Remover (6354), remove the
clutch front plate from the compressor (Fig. 4). When
installing the front plate, select the proper shims to
achieve .5 to .9 mm (.020 to .035 inch) air gap to the
pulley surface (Fig. 5). To install front plate, align shaft
key to groove in front plate hub. Push on until it seats,
and measure the air gap (Fig. 6).
(3) Remove clutch pulley retaining snap ring (Fig. 7)
and pull the pulley from the assembly (Fig. 8).
(4) Remove the clutch coil wire lead strap screw.
(5) Remove clutch coil retaining snap ring (Fig. 9)
and pull the coil from the assembly (Fig. 10). When
installing the clutch coil, align the pin on the front of
the compressor to the middle hole in the hub of the coil.
Position the pin in the snap ring gap.
To install, reverse the preceding operation.
COMPRESSOR FRONT SHAFT SEAL
REMOVAL
(1) Discharge the refrigerant system.
(2) Remove A/C compressor.
Fig. 3 Remove or Install Front Plate Retaining Nut
Fig. 4 Remove Front Plate
Fig. 5 Install Front Plate and Shims
Fig. 6 Measure Front Plate Air Gap
Fig. 7 Remove or Install Pulley Snap Ring
24 - 28
HEATING AND AIR CONDITIONING
.
(3) Remove the compressor clutch assembly and
shaft key.
(4) Remove the felt contaminant absorber and re-
tainer (Fig. 11).
(5) Using a mineral spirits based solvent, thoroughly
clean and dry the seal end of the compressor. This will
help to avoid refrigerant system contamination.
(6) Remove the snap ring shaft seal retainer (Fig.
12). Do not use the old snap ring to assemble.
(7) Using Seal Remover/Installer (6429), remove the
shaft seal (Fig. 13).
Fig. 12 Shaft Seal Snap Ring
Fig. 13 Remove Shaft Seal
Fig. 8 Remove or Install Pulley
Fig. 9 Remove or Install Clutch Coil Snap Ring
Fig. 10 Remove or Install Clutch Coil
Fig. 11 Felt Contaminant Absorber
.
HEATING AND AIR CONDITIONING
24 - 29
INSTALLATION
(1) Lubricate the new shaft seal with refrigerant oil.
(2) Place Seal Protector (6231) over the end of com-
pressor shaft (Fig. 14). Use the larger flat end of the
remover/installer and push the seal in until it seats
and the snap ring groove is visible above the seal (Fig.
15).
(3) Install clutch/coil assembly.
(4) Install compressor.
(5) Evacuate and charge the refrigerant system. If
oil loss of 3 ml (1 oz) or greater is suspected, refer to Oil
Level in the Refrigerant Service Procedures section.
COMPRESSOR HIGH PRESSURE CUT-OUT SWITCH
REMOVAL AND INSTALLATION
(1) Discharge the refrigerant system.
(2) Disconnect wire connector from the high pres-
sure cut-out switch (Fig. 16).
(3) Remove snap ring securing the switch in the
compressor end cover (Fig. 17).
(4) Pull switch straight out from end cover. Remove
and discard used O-ring seal (Fig. 18).
CAUTION: The High Pressure Cut-Out switch service
kit has two snap rings. One snap ring is black and the
other is silver. Use the one that is the same color as
the original snap ring.
Fig. 14 Shaft Seal Protector
Fig. 15 Install Shaft Seal
Fig. 16 High Pressure Cut-out Switch
Fig. 17 Remove or Install Snap Ring
Fig. 18 Remove or Install High Pressure Cut-out
Switch
24 - 30
HEATING AND AIR CONDITIONING
.
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