2005 CHRYSLER VOYAGER engine

(10) Reconnect the body wire harness connector for
the rear HVAC housing to the rear HVAC wire har-
ness connector located near the expansion valve at
the back of the housing.
(11) Reinstall the rear distribution duct onto the
rear HVAC housing and the rear roof duct (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION/AIR OUTLETS - INSTALLATION).
(12) Reinstall the right quarter trim panel and
right D-pillar trim panel onto the quarter inner
panel (Refer to 23 - BODY/INTERIOR/QUARTER
TRIM PANEL - INSTALLATION).
(13) Raise and support the vehicle.
(14) Install the three nuts that secure the rear
HVAC housing mounting studs to the rear floor panel
behind the right rear wheel housing. Tighten the
nuts to 9 N´m (80 in. lbs.).
(15) Remove the tape or plugs from the underbody
refrigerant line fittings and both ports in the rear
evaporator extension line sealing plate.
(16) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the underbody
refrigerant line fittings.
(17) Reconnect the underbody refrigerant line seal-
ing plate to the evaporator extension line tapping
plate.
(18) Install the nut that secures the underbody
refrigerant line sealing plate to the evaporator exten-
sion line tapping plate. Tighten the nut to 23 N´m
(17 ft. lbs.).
(19) Lower the vehicle.
(20) Reconnect the battery negative cable.
(21) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(22) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(23) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
(24) Run the HVAC Cooldown test to verify proper
operation (Refer to 24 - HEATING & AIR CONDI-
TIONING - DIAGNOSIS AND TESTING).REAR FLOOR HEAT DUCT
REMOVAL
(1) Remove the trim from the right quarter inner
panel (Refer to 23 - BODY/INTERIOR/RIGHT
QUARTER TRIM PANEL - REMOVAL).
(2) Remove the two screws that secure the rear
floor heat duct to the right quarter inner panel (Fig.
9).
(3) Slide the rear floor heat duct forward far
enough to disengage it from the outlet on the front of
the rear HVAC housing.
(4) Remove the rear floor heat duct from the vehi-
cle.
INSTALLATION
(1) Align the inlet end of rear floor heat duct with
the outlet on the front of the rear HVAC housing.
(2) Slide the rear floor heat duct rearward far
enough to fully engage the inlet end of the duct with
the outlet on the rear HVAC housing.
(3) Install the two screws that secure the rear floor
heat duct to the right quarter inner panel. Tighten
the screws to 2 N´m (17 in. lbs.).
(4) Reinstall the trim onto the right quarter inner
panel (Refer to 23 - BODY/INTERIOR/RIGHT
QUARTER TRIM PANEL - INSTALLATION).
Fig. 9 Rear Floor Heat Duct
1 - REAR FLOOR HEAT DUCT
2 - REAR HVAC HOUSING OUTLET
3 - SCREW (2)
RSDISTRIBUTION - REAR24-63
HVAC HOUSING (Continued)

PLUMBING - FRONT
TABLE OF CONTENTS
page page
PLUMBING - FRONT
DESCRIPTION.........................65
OPERATION...........................65
WARNING
ENGINE COOLING SYSTEM.............65
A/C SYSTEM.........................66
CAUTION - A/C SYSTEM.................66
DIAGNOSIS AND TESTING
REFRIGERANT SYSTEM LEAKS..........67
SYSTEM CHARGE LEVEL TEST..........67
STANDARD PROCEDURE
HANDLING TUBING AND FITTINGS.......69
REFRIGERANT SYSTEM SERVICE
EQUIPMENT.........................69
REFRIGERANT SYSTEM RECOVERY......70
REFRIGERANT SYSTEM EVACUATE......70
REFRIGERANT SYSTEM CHARGE........71
A/C COMPRESSOR
DESCRIPTION
A/C COMPRESSOR....................72
HIGH PRESSURE RELIEF VALVE.........72
OPERATION
A/C COMPRESSOR....................72
HIGH PRESSURE RELIEF VALVE.........72
DIAGNOSIS AND TESTING
A/C COMPRESSOR NOISE DIAGNOSIS....72
REMOVAL
A/C COMPRESSOR....................73
A/C COMPRESSOR MOUNTING BRACKET -
2.4L ENGINE.........................74
INSTALLATION
A/C COMPRESSOR....................74
A/C COMPRESSOR MOUNTING BRACKET -
2.4L ENGINE.........................75
A/C CONDENSER
DESCRIPTION.........................75
OPERATION...........................75
REMOVAL
2.4L/3.3L/3.8L ENGINES................76
2.5L/2.8L DIESEL ENGINES..............77
INSTALLATION
2.4L/3.3L/3.8L ENGINES................77
2.5L/2.8L DIESEL ENGINES..............78
A/C DISCHARGE LINE
REMOVAL.............................79
INSTALLATION.........................80
A/C EVAPORATOR
DESCRIPTION.........................80OPERATION...........................80
REMOVAL.............................81
INSTALLATION.........................81
EXPANSION VALVE
DESCRIPTION.........................81
OPERATION...........................81
DIAGNOSIS AND TESTING
FRONT A/C EXPANSION VALVE..........82
REMOVAL.............................82
INSTALLATION.........................83
HEATER CORE
DESCRIPTION.........................83
OPERATION...........................84
REMOVAL
FRONT HEATER CORE TUBES...........84
FRONT HEATER CORE.................85
INSTALLATION
FRONT HEATER CORE TUBES...........85
FRONT HEATER CORE.................86
HEATER INLET HOSE
REMOVAL.............................86
INSTALLATION.........................87
HEATER RETURN HOSE
REMOVAL.............................88
INSTALLATION.........................89
LIQUID LINE
REMOVAL.............................89
INSTALLATION.........................91
RECEIVER / DRIER
DESCRIPTION.........................92
OPERATION...........................92
REMOVAL.............................92
INSTALLATION.........................93
REFRIGERANT
DESCRIPTION.........................93
OPERATION...........................94
REFRIGERANT OIL
DESCRIPTION.........................94
OPERATION...........................94
STANDARD PROCEDURE
REFRIGERANT OIL LEVEL..............94
SERVICE PORT VALVE CORE
DESCRIPTION.........................95
REMOVAL.............................95
INSTALLATION.........................95
SUCTION LINE
REMOVAL.............................96
INSTALLATION.........................97
24 - 64 PLUMBING - FRONTRS

PLUMBING - FRONT
DESCRIPTION
CAUTION: The system must be completely empty
before opening any fitting or connection in the
refrigeration system. Open fittings with caution
even after the system has been emptied. If any
pressure is noticed as a fitting is loosened,
retighten fitting and evacuate the system again.
The use of correct wrenches when making connec-
tions is very important. Improper wrenches or
improper use of wrenches can damage the fittings.
The internal parts of the A/C system will remain sta-
ble as long as moisture-free refrigerant and refrig-
erant oil is used. Abnormal amounts of dirt,
moisture or air can upset the chemical stability.
This may cause operational troubles or even seri-
ous damage if present in more than very small
quantities. Before disconnecting a refrigerant line
or hose, clean the outside of the fittings thoroughly
to prevent contamination from entering the refriger-
ant system.
When opening a refrigeration system, have every-
thing you will need to repair the system ready to
minimize the amount of time the system is opened.
Cap or plug all refrigerant line fittings as soon as
they are opened. This will help prevent the entrance
of dirt and moisture. All new lines and components
should be capped or sealed until they are ready to
be used. Before connecting a refrigerant line or
hose, clean the outside of the fittings thoroughly to
prevent contamination from entering the refrigerant
system.
All tools, including the refrigerant dispensing mani-
fold, manifold gauge set and test hoses should be
kept clean and dry.
The A/C refrigerant lines and hoses are used to
carry the refrigerant between the various A/C system
components. The refrigerant lines and hoses for the
R-134a system on this vehicle consist of a barrier-
hose design with a nylon tube sandwiched between
rubber layers. The nylon tube helps to contain the
R-134a refrigerant, which has a smaller molecular
structure than R-12 refrigerant. The ends of the
refrigerant lines are made from lightweight alumi-
num or steel, and commonly use braze-less fittings.Any kinks or sharp bends in the refrigerant lines
and hoses will reduce the capacity of the entire A/C
system and can reduce the flow of refrigerant in the
system. The radius of all bends in the flexible hose
refrigerant lines should be at least ten times the
diameter of the hose and the refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) away from the exhaust manifold(s) and
exhaust pipe(s).
OPERATION
High pressures are produced in the refrigerant sys-
tem when the A/C compressor is operating. Extreme
care must be exercised to make sure that each of the
refrigerant system connections is pressure-tight and
leak free. It is a good practice to inspect all flexible
hose refrigerant lines at least once a year to make
sure they are in good condition and properly routed.
The refrigerant lines and hoses are coupled to
other A/C system components with block-type fit-
tings. An O-ring seal, or a flat steel gasket with an
integral O-ring (dual plane seal), is used to mate the
refrigerant line fittings with A/C system components
to ensure the integrity of the refrigerant system.
The refrigerant lines and hoses cannot be repaired
and, if faulty or damaged, they must be replaced.
WARNING
ENGINE COOLING SYSTEM
WARNING: THE ENGINE COOLING SYSTEM IS
DESIGNED TO DEVELOP INTERNAL PRESSURES
OF 97 TO 123 KILOPASCALS (14 TO 18 POUNDS
PER SQUARE INCH). DO NOT REMOVE OR
LOOSEN THE COOLANT PRESSURE CAP, CYLIN-
DER BLOCK DRAIN PLUGS, RADIATOR DRAIN,
RADIATOR HOSES, HEATER HOSES, OR HOSE
CLAMPS WHILE THE ENGINE COOLING SYSTEM IS
HOT AND UNDER PRESSURE. FAILURE TO
OBSERVE THIS WARNING CAN RESULT IN SERI-
OUS BURNS FROM THE HEATED ENGINE COOL-
ANT. ALLOW THE VEHICLE TO COOL FOR A
MINIMUM OF 15 MINUTES BEFORE OPENING THE
COOLING SYSTEM FOR SERVICE.
RSPLUMBING - FRONT24-65

DIAGNOSIS AND TESTING
REFRIGERANT SYSTEM LEAKS
WARNING: R-134a SERVICE EQUIPMENT OR VEHI-
CLE A/C SYSTEM SHOULD NOT BE PRESSURE
TESTED OR LEAK TESTED WITH COMPRESSED
AIR. MIXTURE OF AIR and R-134a CAN BE COMBUS-
TIBLE AT ELEVATED PRESSURES. THESE MIX-
TURES ARE POTENTIALLY DANGEROUS AND MAY
RESULT IN FIRE OR EXPLOSION CAUSING INJURY
OR PROPERTY DAMAGE.
AVOID BREATHING A/C REFRIGERANT AND LUBRI-
CANT VAPOR OR MIST. EXPOSURE MAY IRRITATE
EYES, NOSE AND THROAT. USE ONLY APPROVED
SERVICE EQUIPMENT MEETING SAE REQUIRE-
MENTS TO DISCHARGE R-134a SYSTEM. IF ACCI-
DENTAL SYSTEM DISCHARGE OCCURS, VENTILATE
WORK AREA BEFORE RESUMING SERVICE.
If the A/C system is not cooling properly, determine
if the refrigerant system is fully charged with R-134a
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT/REFRIGERANT - DIAGNO-
SIS AND TESTING - REFRIGERANT SYSTEM
CHARGE LEVEL). If while performing this test A/C
liquid line pressure is less than 345 kPa (50 psi) pro-
ceed to System Empty procedure. If liquid line pres-
sure is greater than 345 kPa (50 psi) proceed to
System Low procedure. If the refrigerant system is
empty or low in refrigerant charge, a leak at any line
fitting or component seal is likely. A review of the fit-
tings, lines and components for oily residue is an
indication of the leak location.
To detect a leak in the refrigerant system, perform
one of the following procedures as indicated by the
results of the refrigerant system charge level test.
SYSTEM EMPTY
(1) Evacuate the refrigerant system to the lowest
degree of vacuum possible (approx. 28 in Hg.) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - FRONT/REFRIGERANT - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM EVACUATE).
Determine if the system holds a vacuum for 15 min-
utes. If vacuum is held, a leak is probably not
present. If system will not maintain vacuum level,
proceed with this procedure.
(2) Prepare a 0.284 Kg. (10 oz.) refrigerant charge
to be injected into the system.
(3) Connect and dispense 0.284 Kg. (10 oz.) of
refrigerant into the evacuated refrigerant system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT/REFRIGERANT - STANDARD
PROCEDURE - REFRIGERANT SYSTEM CHARGE).
(4) Proceed to the SYSTEM LOW procedures.SYSTEM LOW
(1) Position the vehicle in a wind-free work area.
This will aid in detecting small leaks.
(2) Bring the refrigerant system up to operating
temperature and pressure. This is done by allowing
the engine to run for five minutes with the system
set to the following:
²Transaxle in Park
²Engine idling
²Rear A/C Off (if equipped)
²A/C controls set to 100 percent outside air
²Blower switch in the highest speed position
²A/C in the ON position
²Front windows open
CAUTION: A leak detector designed for R-12 refrig-
erant (only) will not detect leaks in a R-134a refrig-
erant system.
(3) Shut off the vehicle and wait 2 to 7 minutes.
Then use an Electronic Leak Detector that is
designed to detect R-134a type refrigerant and search
for leaks. Fittings, lines, or components that appear
to be oily usually indicates a refrigerant leak. To
inspect the evaporator core for leaks, insert the leak
detector probe into the drain tube opening or a heat
duct. A R-134a dye is available to aid in leak detec-
tion, use only DaimlerChrysler approved refrigerant
dye.
SYSTEM CHARGE LEVEL TEST
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - WARNING - A/C PLUMBING) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - CAUTION - A/C PLUMBING).
NOTE: Always refer to the underhood HVAC Speci-
fication Label for the refrigerant fill specification of
the vehicle being serviced.
The procedure that follows should be used to deter-
mine whether the refrigerant system contains the
proper refrigerant charge. Symptoms of an improper
refrigerant charge (low) include: poor air conditioner
performance, fog emitted from the air conditioner
outlets, a hissing sound from the expansion valve/
evaporator area. There are two different methods
with which the refrigerant charge level may be
tested:
1. Using a DRBIIItscan tool, a thermocouple and
the Charge Determination Chart (Fig. 1). Refer to
the appropriate diagnostic information.
RSPLUMBING - FRONT24-67
PLUMBING - FRONT (Continued)

2. Using a manifold gauge set, a thermocouple and
the Charge Determination Chart (Fig. 1).
A temperature probe is required to measure liquid
line temperature. The clamp-on, Type K thermocou-
ple temperature probe used in this procedure is
available through the DaimlerChrysler Professional
Service Equipment (PSE) program. This probe (PSE
#66-324-0014 or #80PK-1A) is compatible with tem-
perature-measuring instruments that accept Type K
thermocouples, and have a miniature connector
input. Other temperature probes are available
through aftermarket sources; however, all references
in this procedure will reflect the use of the probe
made available through the PSE program.
In order to use the temperature probe, a digital
thermometer will also be required. If a digital ther-
mometer is not available, an adapter is available
through the PSE program that will convert any stan-
dard digital multimeter into a digital thermometer.
This adapter is designed to accept any standard Type
K thermocouple. If a digital multimeter is not avail-
able, this tool is also available through the PSE pro-
gram.NOTE: When connecting the service equipment
couplings to the refrigerant system service ports,
be certain that the valve of each coupling is fully
closed. This will reduce the amount of effort
required to make the connection.
(1) Remove the caps from the refrigerant system
service ports and attach a manifold gauge set or a
R-134a refrigerant recovery/recycling/charging sta-
tion that meets SAE Standard J2210 to the refriger-
ant system.
(2) Attach a clamp-on thermocouple to the liquid
line. The thermocouple must be placed as close to the
A/C pressure transducer as possible to accurately
observe liquid line temperature.
(3) Bring the refrigerant system up to operating
temperature and pressure. This is done by allowing
the engine to run at idle under the following condi-
tions for five minutes.
(a) Front windows are open.
(b) Transaxle in Park.
(c) Front heater-A/C controls set to outside air,
full cool, panel mode, blower high, and compressor
engaged.
(d) If the vehicle is so equipped, the rear heater-
A/C controls must be set to full cool and blower
high.
Fig. 1 Charge Determination Chart, Ambient Test Condition 85ÉF
24 - 68 PLUMBING - FRONTRS
PLUMBING - FRONT (Continued)

(4) Open both the suction and discharge valves,
then open the charge valve to allow the heated
refrigerant to flow into the system.
(5) When the transfer of refrigerant has stopped,
close both the suction and discharge valves.
(6) If all of the refrigerant charge did not transfer
from the dispensing device, open all of the windows
in the vehicle and set the heater-air conditioner con-
trols so that the compressor is engaged and the
blower motor is operating at its lowest speed setting.
Run the engine at a steady high idle (about 1400
rpm). If the compressor will not engage, test the com-
pressor clutch control circuit and repair as required.
(7) Open the suction valve to allow the remaining
refrigerant to transfer to the refrigerant system.
WARNING: TAKE CARE NOT TO OPEN THE DIS-
CHARGE (HIGH PRESSURE) VALVE AT THIS TIME.
(8) Close the suction valve and test the system
performance. (Refer to 24 - HEATING & AIR CON-
DITIONING - STANDARD PROCEDURE - A/C PER-
FORMANCE TEST).
(9) Disconnect the charging station and manifold
gauge set from the refrigerant system service ports.
(10) Reinstall the caps onto the refrigerant system
service ports.
(11) Run the HVAC Control Cooldown test to ver-
ify proper operation(Refer to 24 - HEATING & AIR
CONDITIONING - DIAGNOSIS AND TESTING).
A/C COMPRESSOR
DESCRIPTION
A/C COMPRESSOR
Vehicles equipped with the 2.4L gasoline, 2.5L die-
sel, 2.8L diesel and 3.3L gasoline engines with the
front heating-A/C system only, use the Denso 10S17
A/C compressor. Vehicles equipped with the 3.3L and
the 3.8L gasoline engines with the optional rear heat-
ing-A/C system use the Denso 10S20 A/C compressor.
Both A/C compressors include an integral high pres-
sure relief valve. The A/C compressor is secured to a
mounting bracket on the 2.4L gasoline engine and
directly to the cylinder block on the 2.5L diesel, 2.8L
diesel, 3.3L gasoline and 3.8L gasoline engines.
HIGH PRESSURE RELIEF VALVE
A high pressure relief valve is located on the rear
of the A/C compressor. This mechanical valve is
designed to vent refrigerant from the A/C system to
protect against damage to the compressor and other
system components, caused by condenser air flow
restriction or an overcharge of refrigerant.
OPERATION
A/C COMPRESSOR
The A/C compressor is driven by the engine
through an electric clutch, drive pulley and belt
arrangement. The compressor is lubricated by refrig-
erant oil that is circulated throughout the refrigerant
system with the refrigerant.
The compressor draws in low-pressure refrigerant
vapor from the evaporator through its suction port. It
then compresses the refrigerant into a high-pressure,
high-temperature refrigerant vapor. The compressor
pumps the high-pressure refrigerant vapor to the
condenser through the compressor discharge port.
The compressor cannot be repaired. If faulty or
damaged, the entire compressor assembly must be
replaced. The compressor clutch, pulley and clutch
coil are available for service.
HIGH PRESSURE RELIEF VALVE
The high pressure relief valve vents the system
when a discharge pressure of 3445 to 4135 kPa (500
to 600 psi) or above is reached. The valve closes
when a minimum discharge pressure of 2756 kPa
(400 psi) is reached.
The high pressure relief valve vents only enough
refrigerant to reduce the system pressure, and then
re-seats itself. The majority of the refrigerant is con-
served in the system. If the valve vents refrigerant, it
does not mean that the valve is faulty.
The high pressure relief valve is a factory-cali-
brated unit. The valve cannot be adjusted or
repaired, and must not be removed or otherwise dis-
turbed. The valve is only serviced as a part of the
compressor assembly.
DIAGNOSIS AND TESTING
A/C COMPRESSOR NOISE DIAGNOSIS
Excessive noise while the air conditioning compres-
sor is operating can be caused by loose compressor
mounts, a loose compressor clutch, or high operating
pressures in the refrigerant system. Verify compres-
sor drive belt condition, proper compressor mounting,
correct refrigerant charge level, and compressor head
pressure before compressor repair is performed.
With the close tolerances within the compressor, it
is possible to experience a temporary lockup. The
longer the compressor is inactive, the more likely the
condition is to occur. This condition is the result of
normal refrigerant migration within the refrigerant
system caused by ambient temperature changes. The
refrigerant migration may wash the refrigerant oil
out of the compressor.
24 - 72 PLUMBING - FRONTRS
PLUMBING - FRONT (Continued)

NOTE: Prior to a vehicle being removed from ser-
vice or stored for more than two weeks, the com-
pressor should be operated to ensure adequate
refrigerant oil distribution throughout the system
components. Turn on the air conditioner for a min-
imum of five minutes with outside air and the high-
est blower speed selected.
BELT NOISE
If the compressor drive belt slips at initial start-up,
it does not necessarily mean the compressor has
failed. The following procedure can be used to iden-
tify a compressor drive belt noise problem.
A. Start the vehicle and run at idle.
B. Turn the air conditioner On and listen for belt
squeal.
C. If belt squeal is heard, turn the air conditioner
Off immediately.
If the belt squeal stops when the air conditioner is
turned Off, perform the following repair procedures.
(1) Using an appropriate sized oil filter wrench or
a strap wrench, grasp the outer diameter of the com-
pressor clutch hub. While facing the compressor,
rotate the hub clockwise, then counterclockwise. If
the hub rotates, proceed to the next step. If the hub
will not rotate, the compressor is internally damaged,
and must be replaced.
(2) Turn the hub clockwise five complete revolu-
tions and remove the tool.
(3) Start the vehicle and run at idle.
(4) Turn the air conditioner On. Observe the com-
pressor and the system for normal operation, noting
cooling performance and noise levels. Operate for five
minutes before turning the air conditioner Off. If
acceptable cooling performance is observed during
compressor operation, the compressor does not need
to be replaced.
(5) Inspect the drive belt for wear, damage, and
proper tension. (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - DIAGNOSIS AND TEST-
ING).
REMOVAL
A/C COMPRESSOR
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - WARNING - A/C PLUMBING) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - CAUTION - A/C PLUMBING).(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT SYSTEM
RECOVERY).
(2) Disconnect and isolate the negative battery
cable.
(3) Remove the nuts that secure the A/C suction
line and the A/C discharge line to the A/C compres-
sor.
(4) Disconnect the A/C suction line and the A/C
discharge line from the A/C compressor.
(5) Remove the O-ring seal and gasket from the
suction and discharge line fittings and discard.
(6) Install plugs in, or tape over the opened suc-
tion and discharge fittings and the compressor ports.
(7) Raise and support the vehicle.
(8) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(9) Disconnect the wire harness connector from the
compressor clutch coil wire connector located on the
top of the A/C compressor (Fig. 4) or (Fig. 5).
(10) On models with the 2.4L, 2.5L and 2.8L
engine, remove the four bolts that secure the A/C
compressor to the mounting bracket on the engine
(2.4L), or the cylinder block (2.5L/2.8L).
Fig. 4 A/C Compressor - 2.4L Shown, 2.5L/2.8L
Typical
1 - CLUTCH COIL WIRE CONNECTOR
2 - DISCHARGE PORT
3 - A/C COMPRESSOR
4 - SUCTION PORT
5 - BOLT (4)
6 - A/C COMPRESSOR MOUNTING BRACKET
RSPLUMBING - FRONT24-73
A/C COMPRESSOR (Continued)

(11) On models with the 3.3L and 3.8L engines,
disengage the retainer on the engine wire harness
compressor clutch coil take out from the bracket on
the top of the A/C compressor and remove the two
bolts and the two nuts that secure the A/C compres-
sor to the engine.
NOTE: If a replacement A/C compressor is being
installed, be certain to drain and measure the refrig-
erant oil contained in the removed compressor.
This will determine how much oil the replacement
A/C compressor must contain before it is installed
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT/REFRIGERANT OIL - STAN-
DARD PROCEDURE - REFRIGERANT OIL LEVEL).
NOTE: The receiver/drier should always be replaced
when the A/C compressor is replaced. This will help
remove any contaminants including moisture from
the system.
(12) Remove the A/C compressor from the engine
compartment.
A/C COMPRESSOR MOUNTING BRACKET -
2.4L ENGINE
(1) Remove the A/C compressor from the mounting
bracket (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/COMPRESSOR - REMOVAL).
(2) Remove the four bolts that secure the compres-
sor mounting bracket to the engine (Fig. 6).(3) Remove the compressor mounting bracket from
the engine.
INSTALLATION
A/C COMPRESSOR
NOTE: If a replacement A/C compressor is being
installed, be certain to check the refrigerant oil level
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT/REFRIGERANT OIL - STAN-
DARD PROCEDURE - REFRIGERANT OIL LEVEL).
Use only refrigerant oil of the type recommended
for the A/C compressor in the vehicle.
NOTE: The receiver/drier should always be replaced
when the A/C compressor is replaced. This help will
remove any contaminants including moisture from
the refrigerant system.
(1) Position the A/C compressor into the engine
compartment.
(2) On models with the 2.4L, 2.5L and 2.8L engine,
loosely install the four bolts that secure the A/C com-
pressor to the mounting bracket on the engine (2.4L),
or the cylinder block (2.5L/2.8L). Tighten the bolts to
28 N´m (21 ft. lbs.).
(3) On models with the 3.3L and 3.8L engines,
loosely install the two bolts and the two nuts that
secure the A/C compressor to the engine and engage
the retainer on the engine wire harness compressor
clutch coil take out to the bracket on the top of the
A/C compressor. Tighten each of the fasteners using
the following sequence to 54 N´m (40 ft. lbs.).
²The upper nut at the front of the compressor.
²The lower nut at the front of the compressor.
Fig. 5 A/C Compressor - 3.8L Shown, 3.3L Typical
1 - A/C COMPRESSOR
2 - BOLT (2)
3 - NUT (2)
Fig. 6 Compressor Mounting Bracket - 2.4L Engine
1 - MOUNTING BRACKET
2 - BOLTS (4)
3 - ENGINE
24 - 74 PLUMBING - FRONTRS
A/C COMPRESSOR (Continued)