Dodge Caliber. Manual — part 1428
NOTE: Illustrations shown with A/C compressor removed from engine for clarity.
NOTE: Gasoline engine model A/C compressor
pulley and drive hub shown. Diesel model similar.
1. Raise and support the vehicle.
2. Remove the splash shield from the right side frame
rail
(refer
to
23
-
BODY/EXTERIOR/SPLASH
SHIELD-RIGHT SIDE RAIL - REMOVAL).
3. Remove the accessory drive belt (refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
NOTE: The drive hub on the gasoline engine
model A/C compressor is removed using special
tool 9907. The drive hub on the diesel engine
model is removed using an open end wrench.
4. Using spanner wrench (Special Tool 9907 or equiv-
alent) (2) or an open end wrench (depending on engine application), hold the drive hub (1) while rotating the
shaft of the A/C compressor (3) clockwise using a 7 mm (9/32 in.) deep well socket and a ratchet (4) and remove
the drive hub from the compressor.
5. Remove the shim (1) from the shaft of the A/C
compressor (2).
6. Using snap ring pliers (Special Tool 9764 or equiv-
alent) (5), remove the external snap ring (3) that
secures the pulley and bearing assembly (4) to the
front of the A/C compressor and remove the pulley
and bearing assembly from the compressor.
A/C COMPRESSOR
WARNING: Review safety precautions and warnings in this group before performing this procedure (refer to
24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) and (refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - CAUTION). Failure to follow the warnings and cautions could result in possible personal
injury or death.
PM
PLUMBING
24 - 129
1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system
(refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING
-
STANDARD
PROCEDURE
-
REFRIGERANT SYSTEM RECOVERY).
3. Raise and support the vehicle.
4. Remove the splash shield from the right side frame
rail
(refer
to
23
-
BODY/EXTERIOR/SPLASH
SHIELD-RIGHT SIDE RAIL - REMOVAL).
5. Remove the accessory drive belt (refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
6. Disconnect the engine wire harness (1) from the
compressor control valve (2).
7. Remove the nuts (4) that secure the A/C discharge
line (5) and the A/C suction line (6) to the A/C com-
pressor (3).
8. Disconnect the A/C discharge and suction lines from the A/C compressor and remove and discard the O-ring
seals and gaskets.
9. Support the A/C compressor (1) and remove the
three bolts (2) that secure the compressor to the
engine and remove the compressor.
10. Install plugs in, or tape over the opened refriger-
ant line fittings and compressor ports.
INSPECTION
HUB AND PULLEY INSPECTION
NOTE: The A/C compressor pulley and bearing assembly can be serviced separately in the event of damage
or wear to the pulley or bearing. However, the compressor drive hub itself is not serviceable. In the event of
drive hub failure, the A/C compressor, drive hub and pulley and bearing must be replaced as an assembly.
NOTE: The A/C compressor hub and pulley and bearing assembly can be serviced in the vehicle. The refrig-
erant system can remain fully charged during pulley and bearing replacement.
NOTE: Typical A/C compressor pulley drive hub shown.
24 - 130
PLUMBING
PM
The bridges (1) located on the compressor hub (2) are
designed to break away in the event of compressor
seizure. Examine the bridges for separation or cracks
(3). Damage to the bridges are an indication of exces-
sive compressor torque, which is most likely caused
by compressor failure.
Check the pulley bearing (4) for roughness or exces-
sive leakage of grease. Examine the pulley dampen-
ers (5) for deterioration or damage. Inspect the belt
surfaces of the pulley (4) for wear. The pulley should
be replaced if there is excessive wear or scoring. If
the pulley surfaces are oily, inspect the shaft and nose
area of the A/C compressor for refrigerant oil. If refrig-
erant oil is found, the compressor shaft seal is leaking
and the A/C compressor must be replaced.
Replace the A/C compressor pulley and bearing
assembly if wear or damage is found.
INSTALLATION
PULLEY AND BEARING
NOTE: Illustrations shown with A/C compressor removed from engine for clarity.
CAUTION: The pulley and hub are both con-
structed from composite materials and can be eas-
ily damaged if not properly installed. Always use
care when installing the pulley and hub onto the
A/C compressor.
1. Install the pulley and bearing assembly (4) onto the
front of the A/C compressor (2). If necessary, place
a block of wood over the pulley surface and gently
tap on the wood with a light weight hammer.
CAUTION: The snap ring must be fully and prop-
erly seated in the groove or it will vibrate out,
resulting in a pulley failure and possible severe
damage to the A/C compressor.
NOTE: A new snap ring must be used to secure
the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward.
2. Using snap ring pliers (Special Tool 9764 or equivalent) (5), install the external snap ring (3) that secures the
pulley and bearing assembly to the front of the A/C compressor. Be certain that the snap ring is fully and properly
seated in the groove.
3. Install the shim (1) onto the shaft of the A/C compressor.
PM
PLUMBING
24 - 131
NOTE: Gasoline engine model A/C compressor
pulley and drive hub shown. Diesel model similar.
4. Align the tabs of the drive hub (1) between the rub-
ber dampers of the pulley and bearing assembly
(4) and position the drive hub onto the shaft of the
A/C compressor (3) (for more information, refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
COMPRESSOR-A/C-HUB
AND
PULLEY
-
DESCRIPTION).
NOTE: The drive hub on the gasoline engine
model A/C compressor is installed using special
tool 9907. The drive hub on the diesel engine
model is installed using an open end wrench.
5. Rotate the shaft of the A/C compressor counter-
clockwise using a 7 mm (9/32 in.) deep well socket
and a ratchet (5) while holding the drive hub using spanner wrench (Special Tool 9907 or equivalent) (2) or an
open end wrench (depending on engine application). Tighten the drive hub securely onto the compressor shaft.
6. Install the accessory drive belt (refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
7. Install the splash shield onto the right side frame rail (refer to 23 - BODY/EXTERIOR/SPLASH SHIELD-RIGHT
SIDE RAIL - INSTALLATION).
8. Lower the vehicle.
A/C COMPRESSOR
CAUTION: When replacing an A/C compressor, be certain to check and adjust the refrigerant system oil
level (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCE-
DURE - REFRIGERANT OIL LEVEL). Failure to properly adjust the refrigerant oil level can prevent the A/C
system from operating as designed and can cause serious A/C compressor damage.
NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is
opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system
leak.
1. If the A/C compressor (1) is being replaced, the
refrigerant oil in the old compressor must be first
drained and measured. Then drain all of the oil
from the new A/C compressor and fill the new com-
pressor with the same amount of new refrigerant oil
that was drained out of the old compressor (refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
REFRIGERANT OIL - STANDARD PROCEDURE -
REFRIGERANT OIL LEVEL). Use only refrigerant
oil of the type recommended for the A/C compres-
sor in the vehicle.
2. Position the A/C compressor into the engine com-
partment.
3. Install the three bolts (2) that secure the A/C com-
pressor to the engine. Tighten the bolts to 25 N·m
(18 ft. lbs.).
24 - 132
PLUMBING
PM
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