Chrysler Front Wheel Drive Cars 6-CYL 1988-1995 Repair Information

Compressor

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REMOVAL & INSTALLATION



The A/C compressor may be removed and positioned without discharging the refrigerant system. Discharging is not normally necessary when removing the A/C compressor clutch/coil assembly, engine, cylinder head, or alternator. Simply support the compressor with strong wire from the vehicle's frame with the refrigerant lines connected. Do not disconnect the refrigerant lines if performing this.


CAUTION
Do not disconnect the refrigerant lines without having the system first discharged by a qualified professional mechanic with an approved recovery/recycling machine.

3.3L and 3.8L Engines

See Figure 1

If the compressor must be completely removed from the car for repairs, the system must be discharged before disconnecting the lines. Also note that you will need caps or another positive method to tightly seal the refrigerant lines immediately after you open them.

  1. Disconnect the negative battery cable. Have the system discharged by a qualified professional mechanic using an approved recovery/recycling machine. Unfasten the clutch electrical connector.
  2.  
  3. Once the system has been discharged, unbolt the connections at the compressor and plug all four openings.
  4.  
  5. Remove the tension from the serpentine drive belt with a breaker bar or long box end wrench, then remove the belt from the A/C compressor pulley.
  6.  
  7. Support the compressor. Remove the two mounting bolts from the lower side of the compressor and the two mounting nuts from above it. Remove the compressor.
  8.  
  9. At this point, the compressor mounting bracket can be removed from the engine block.
  10.  



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Fig. Fig. 1: A/C compressor and mounting bracket assembly

To install:
  1. Install the compressor mounting bracket and mounting bolts.
  2.  
  3. Position the compressor on the bracket and install the 2 mounting bolts and 2 mounting nuts. Tighten the bolts and nuts to 40 ft. lbs. (54 Nm).
  4.  
  5. Install the serpentine drive belt. Refer to General Information & Maintenance for the correct routing and adjusting procedures.
  6.  
  7. Install the refrigerant lines with new O-rings to the compressor.
  8.  
  9. Connect the electrical wire to the compressor clutch.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Have the system evacuated and recharged by a qualified professional mechanic, utilizing the proper equipment.
  14.  

3.0L Engines

If the compressor must be completely removed from the car for repairs, the system must be discharged before disconnecting the lines. Also note that you will need caps or another positive method to tightly seal the refrigerant lines immediately after you open them.

EXCEPT PREMIER AND MONACO

See Figures 2 through 7

  1. Disconnect the negative battery cable. Have the system discharged by a qualified professional mechanic using an approved recovery/recycling machine. Unfasten the clutch electrical connector.
  2.  
  3. Once the system has been discharged, unbolt the connections at the compressor and plug all four openings.
  4.  



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Fig. Fig. 2: A/C compressor and bracket assembly

  1. Loosen the A/C compressor belt idler pulley tensioning bracket mounting and pivot bolts. Remove the tension from the compressor drive belt, then remove the belt.
  2.  
  3. Support the compressor. Remove the two mounting bolts from the lower side of the compressor and the two mounting nuts from above it. Remove the compressor.
  4.  
  5. At this point, the compressor mounting bracket can be removed from the engine block.
  6.  



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Fig. Fig. 3: To remove the compressor belt, first loosen the center pulley lockbolt, then ...



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Fig. Fig. 4: ... loosen the adjusting bolt and remove the belt from the pulleys



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Fig. Fig. 5: After removing the belt and refrigerant lines, remove the idler pulley assembly



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Fig. Fig. 6: Loosen the compressor mounting bolts, ...



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Fig. Fig. 7: ... remove them from the compressor and bracket, then remove the compressor

To install:
  1. Install the compressor mounting bracket and mounting bolts.
  2.  
  3. Position the compressor on the bracket and install the 2 mounting bolts and 2 mounting nuts. Tighten the bolts and nuts to 40 ft. lbs. (54 Nm).
  4.  
  5. Install the drive belt onto the compressor pulley, crankshaft pulley and adjuster pulley.
  6.  
  7. Tighten the adjuster bolt until only 1 / 2 in. (13mm) deflection can be pushed into the long side of the drive belt. For additional details on belt tensioning, refer to General Information & Maintenance .
  8.  
  9. Tighten the adjuster pulley center nut until snug to lock the adjuster in position.
  10.  
  11. Install the refrigerant lines with new O-rings to the compressor.
  12.  
  13. Connect the electrical wire to the compressor clutch.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Have the system evacuated and recharged by a qualified professional mechanic utilizing the proper equipment.
  18.  

PREMIER AND MONACO

See Figures 8, 9 and 10

  1. Have the A/C system discharged by a qualified professional mechanic with an approved frigerant recovery/recycling machine.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Detach and label the compressor electrical connector.
  6.  
  7. Raise and safely support the front of the vehicle on jackstands.
  8.  
  9. Remove the lower splash shield retaining bolts, then remove the splash shield.
  10.  
  11. Relieve the tension on the drive belt by turning the adjusting bolt.
  12.  
  13. Loosen the alternator mounting bolts.
  14.  
  15. Remove the accessory drive belt.
  16.  
  17. Remove the compressor manifold attaching bolt and separate the manifold from the compressor.
  18.  
  19. Unfasten the compressor mounting bolts and remove the compressor from the engine assembly.
  20.  



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Fig. Fig. 8: Unplug the electrical connector leading to the compressor clutch



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Fig. Fig. 9: Remove the lower splash shield



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Fig. Fig. 10: A/C compressor mounting bolt positions

To install:
  1. If a replacement compressor is being installed, the correct amount of oil should be installed along with the new compressor. Drain and measure the amount of oil in the old compressor. Drain the oil from the new compressor and install the amount of oil removed from the old compressor with an additional 1 oz. (28 grams).
  2.  
  3. Position the compressor and install the compressor mounting bolts. Tighten the bolts to 20 ft. lbs. (27 Nm).
  4.  
  5. Install the accessory drive belt over the alternator pulley.
  6.  
  7. Tighten the alternator pivot bolt to 30 ft. lbs. (40 Nm).
  8.  
  9. Install a belt tension gauge in the middle of the longest span of the accessory drive belt. Ensure that the tension gauge is not touching any engine component.
  10.  
  11. Tighten the adjusting bolt until the correct belt tension is obtained:
    1. New belt-180-200 lbs. (800-900 N).
    2.  
    3. Used belt-140-160 lbs. (623-712 N).
    4.  

  12.  
  13. Tighten the alternator upper mounting bolt to 20 ft. lbs. (27 Nm).
  14.  
  15. Recheck the torque on the pivot bolt.
  16.  
  17. Install the splash shield to the fenderwell.
  18.  
  19. Lower the vehicle.
  20.  
  21. Lubricate the new O-rings of the refrigerant lines with clean refrigerant oil and position them in the O-ring grooves of the compressor manifold.
  22.  
  23. Position the manifold and hose assembly with the new O-rings to the compressor and install the attaching bolts. Tighten the bolts to 28 ft. lbs. (37 Nm).
  24.  
  25. Plug the compressor electrical connector back in.
  26.  
  27. Connect the battery negative cable.
  28.  
  29. Have the A/C system evacuated and recharged by a qualified professional mechanic, utilizing the proper equipment.
  30.