Chrysler Le Baron, Dodge Dynasty, Plymouth Acclaim. Manual — part 192
CAUTION: Refer to Oil Level in the Refrigerant Ser-
vice Procedures section for further details.
(13) Install refrigeration oil (500 SUS) into the
compressor through the suction port.
(14) Check compressor operation for smoothness by
rotating crankshaft at least five full revolutions.
(15) Check front housing clutch coil alignment pin
for proper installation.
(16) Install clutch assembly.
(17) Install compressor.
(18) Evacuate and charge refrigerant system.
COMPRESSOR HIGH-PRESSURE RELIEF VALVE
The high pressure relief valve vents only a small
amount of refrigerant necessary to reduce system
pressure and then reseats itself. The majority of the
refrigerant is conserved in the system. The valve is
calibrated to vent at a pressure of 3100 to 4140 Kpa
(450 to 600 psi). If a valve has vented a small
amount of refrigerant, it does not necessarily mean
the valve is defective.
(HPR) VALVE LOCATION
The HPR Valve is located on the discharge line at
the A/C compressor (Fig. 14).
REMOVAL AND INSTALLATION
(1) Using a refrigerant recovery machine, remove
the refrigerant from the A/C system.
(2) Rotate the high pressure relief valve counterclock-
wise and separate relief valve from the vehicle (Fig. 15).
To install, Reverse the preceding operation using a
new O-ring seal. Evacuate and charge the refrigerant
system.
REFRIGERANT SYSTEM DIAGNOSIS
Refer to the Refrigerant System Diagnosis chart in
this section.
Fig. 13 Felt Retainer and Felt
Fig. 14 High Pressure Relief Valve— Typical
Fig. 15 High Pressure Relief Valve—Typical
Fig. 12 Installing Lip Seal Protector
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HEATING AND AIR CONDITIONING
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REFRIGERANT SYSTEM DIAGNOSIS
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HEATING AND AIR CONDITIONING
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FIXED DISPLACEMENT COMPRESSOR—MODEL TR105
INDEX
page
page
Compressor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Compressor Clutch/Coil Assembly
. . . . . . . . . . . . 32
Compressor Shaft Bearing/Seal
. . . . . . . . . . . . . . 35
Refrigerant System Diagnosis
. . . . . . . . . . . . . . . 36
Thermal Limiter Switch
. . . . . . . . . . . . . . . . . . . . 34
COMPRESSOR
Cleanliness is extremely important when disassem-
bly of the compressor is necessary. The surfaces
around the suction and discharge ports of the com-
pressor should be cleaned thoroughly before opening
the system at these points. If compressor is removed
from vehicle, apply tape to the opened ports to pre-
vent any contamination.
REMOVAL
(1) Disconnect battery negative cable.
(2) Loosen and remove drive belts (refer to Group
7, Cooling System).
(3) Disconnect compressor clutch wire lead.
(4) Using a refrigerant recovery machine, remove
refrigerant from the A/C system.
(5) Remove refrigerant lines from compressor.
(6) Remove compressor attaching bolts.
(7) Remove compressor.
INSTALLATION
(1) Position the compressor on the mount and fit
drive belt.
(2) Tighten the compressor attaching bolts to 41
N
Im (30 ft. lbs.) torque.
(3) Adjust drive belt (see Group 7, Cooling Sys-
tem).
(4) Install refrigerant hoses.
(5) Connect the clutch wire.
(6) Evacuate and charge the system.
(7) Connect the battery negative cable.
COMPRESSOR CLUTCH/COIL ASSEMBLY
CLUTCH INOPERATIVE
The air conditioning compressor clutch electrical
circuit is controlled by the engine controller. The
controller is located in the engine compartment out-
board of the battery.
If the compressor clutch does not engage:
Verify refrigerant charge.
If the compressor clutch still does not engage check
for battery voltage at the low pressure or differential
pressure cut-off switch located on the expansion
valve. If voltage is not detected, refer to:
• Group 8W, Wiring Diagrams.
• The appropriate Powertrain Diagnostic Procedures
Manual for diagnostic information.
If voltage is detected at the cut-off switch, recon-
nect switch. Then check for battery voltage between
the compressor clutch connector terminals.
If voltage is detected, perform A/C Clutch Coil
Tests.
CLUTCH COIL TESTS
(1) Verify battery state of charge. (Test indicator
in battery should be green).
(2) Connect an ammeter (0-10 ampere scale) in se-
ries with the clutch coil terminal. Use a volt meter
(0-20 volt scale) with clip leads measuring voltage
across the battery and A/C clutch.
(3) With A/C control in A/C mode and blower at
low speed, start the engine and run at normal idle.
(4) The A/C clutch should engage immediately and
the clutch voltage should be within two volts of the
battery voltage. If the A/C clutch does not engage,
test the fusible link.
(5) The A/C clutch coil is acceptable if the current
draw is 2.0 to 3.7 amperes at 11.5-12.5 volts at clutch
coil. This is with the work area temperature at 21°C
(70°F). If voltage is more than 12.5 volts, add electri-
cal loads by turning on electrical accessories until
voltage reads below 12.5 volts.
If coil current reads zero, the coil is open and
should be replaced. If the ammeter reading is 4 am-
peres or more, the coil is shorted and should be re-
placed. If the coil voltage is not within two volts of
the battery voltage, test clutch coil feed circuit for
excessive voltage drop.
REMOVAL
(1) Remove the compressor from the mount.
(2) To prevent compressor shaft rotation, install 2
(6 mm) bolts, along with 2 wrenches, to the threaded
holes in the armature plate (Fig. 1). Remove com-
pressor shaft nut.
(3) Tap the armature plate with a plastic and re-
move plate and shim(s).
CAUTION: Do not use screwdrivers between the ar-
mature plate assembly and rotor-pulley to remove
the armature plate. This may damage the armature
plate assembly.
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HEATING AND AIR CONDITIONING
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(4) Remove rotor-pulley retaining snap ring with
Snap Ring Pliers C-4574. Slide rotor-pulley assembly
from compressor. Use a plastic hammer, if necessary.
(5) Loosen the lead wire retaining clamps and re-
move lead wire from the compressor front end plate.
Disconnect the lead wire from the thermal limiter
switch.
(6) Remove the snap ring which secures the field
coil-core assembly to the front boss (Fig. 2). Note the
alignment of field coil-core assembly when removing.
WARNING: TAKE CARE THAT THE SNAP RING
DOES NOT FLY OUT FROM THE GROOVE.
INSPECTION
Examine frictional faces of the rotor-pulley and ar-
mature plate for wear. The pulley and plate should
be replaced if there is excessive wear or scoring. If
the friction surfaces are oily, inspect the shaft nose
area of the compressor for excess oil. If excess oil is
present, the shaft seal is leaking and will have to be
replaced.
Check rotor-pulley bearing for roughness or exces-
sive grease leakage. Check for bearing grease con-
tamination on armature plate faces.
The rotor-pulley and armature plate should be re-
placed as a matched set.
INSTALLATION
(1) Position the back of the field coil-core over the
compressor front boss. This will allow the locating
nipple on the back of the coil to line up with the lo-
cating indentation on the front boss. This ensures
correct angular position of the clutch coil and lead
wire.
(2) Fasten lead wire to the compressor front plate
with the retaining clip. Connect the lead wire to the
thermal limiter switch.
(3) Install field coil-core retaining snap ring (bevel
side outward) with Snap Ring Pliers C-4574. Press
snap ring to make sure it is properly seated in the
groove.
CAUTION: If snap rings on field coil-core and rotor-
pulley are not fully seated, they will vibrate out. A
clutch failure and possible severe damage to the
compressor could result.
(4) Slide pulley assembly onto compressor.
CAUTION: Do not mar the pulley frictional surface.
(5) Install rotor-pulley assembly retaining snap
ring (bevel side outward) with Snap Ring Pliers
C-4574. Press the snap ring to make sure it is prop-
erly seated in the groove.
(6) If the original armature plate assembly and ro-
tor-pulley assembly are to be reused, the old shim(s)
can be used. If not, place a trial stack of shims, 2.54
mm (0.10 in.) thick, on the compressor shaft against
the shoulder of the armature plate.
(7) Install armature plate to the compressor shaft.
Note the machined mating splines (Fig. 3).
Fig. 1 Compressor Shaft Nut Removal/Installation
Fig. 2 Armature Plate/Rotor-Pulley/Field Coil-Core
Fig. 3 Aligning Clutch Plate Splines
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