GrandCaravan 2008

Removal & Installation

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3.3L & 3.8L Engines



Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


CAUTION
Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions may result in serious or fatal injury.


NOTE
The A/C compressor may be removed and repositioned without discharging the refrigerant system or disconnecting the refrigerant lines.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Recover the refrigerant from the refrigerant system. Refer to Maintenance, Discharging The System.
  6.  
  7. Remove the nuts (2 and 4) that secure the A/C discharge line (1) and the A/C suction line (5) to the A/C compressor (3).

    Click image to see an enlarged view

    Fig. Remove the A/C discharge and suction lines-3.3L and 3.8L engines

  8.  
  9. Disconnect the A/C discharge and suction lines from the A/C compressor and remove and discard the O-ring seals and gaskets.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Remove the splash shield from the right side frame rail.
  14.  
  15. Remove the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  16.  
  17. Disconnect the wire harness connector (1) from the A/C compressor (7).
  18.  
  19. Remove the 1 bolt (2) and 3 nuts (5 and 6) that secure the A/C compressor to the engine.
    WARNING
    A stud with an integral spacer (4) is used at the lower rear of the A/C compressor. Always use the fastener designed for this location. Failure to reinstall the stud with spacer will cause serious compressor and accessory drive damage.

  20.  
  21. Remove the A/C compressor from the engine compartment. Remove the 2 studs (3) and the spacer stud (4), as necessary.
  22.  
  23. Install plugs or tape to seal the opened refrigerant line fittings and compressor ports.

    Click image to see an enlarged view

    Fig. Remove the A/C compressor from the engine compartment-3.3L and 3.8L engines

  24.  

To install:

  1. If removed, install the 2 studs (3) and 1 spacer stud (4). Be sure to install the spacer stud in the location shown.
    WARNING
    If the A/C compressor is being replaced, be certain to adjust the refrigerant system oil level. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.


    WARNING
    The A/C receiver/drier must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C receiver/drier can cause serious damage to the replacement A/C compressor.


    NOTE
    When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be removed from the new A/C compressor.


    NOTE
    Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets may result in a refrigerant system leak.

  2.  
  3. If the A/C compressor (7) is being replaced, the refrigerant oil in the old compressor must be first drained and measured. Then, the oil in the new A/C compressor must be drained. Finally, the new compressor must be refilled with the same amount of new refrigerant oil that was drained out of the old compressor. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
    WARNING
    A stud with an integral spacer (4) is used at the lower rear of the A/C compressor. Always use the fastener designed for this location. Failure to reinstall the stud with spacer will cause serious compressor and accessory drive damage.



    Click image to see an enlarged view

    Fig. Refrigerant Oil Capacities Chart

  4.  
  5. Position the A/C compressor onto the engine and tighten the nuts (4) and bolts (3) in the following sequence:
    1. Install the bolt and hand tighten.
    2.  
    3. Install the nuts and hand tighten.
    4.  
    5. Tighten the front 8mm nuts to 17 ft. lbs. (23 Nm).
    6.  
    7. Tighten the rear upper 10mm bolt to 30 ft. lbs. (40 Nm).
    8.  
    9. Tighten the rear lower 10mm stud with the spacer to 30 ft. lbs. (40 Nm).
    10.  

  6.  
  7. Connect the wire harness connector (1) to the A/C compressor clutch coil.
  8.  
  9. Install the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  10.  
  11. Install the splash shield onto the right side frame rail.
  12.  
  13. Lower the vehicle.
  14.  
  15. Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.
  16.  
  17. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and the new gaskets onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  18.  
  19. Install the A/C discharge line (1) and the A/C suction line (5) onto the A/C compressor (3).
  20.  
  21. Install the nuts (2 and 4) that secure the A/C discharge and suction lines to the A/C compressor. Tighten the nuts to 17 ft. lbs. (23 Nm).
  22.  
  23. Reconnect the negative battery cable and tighten the nut to 45 inch lbs. (5 Nm).
  24.  
  25. Evacuate the refrigerant system. Refer to Maintenance, Evacuating The System.
  26.  
  27. Charge the refrigerant system. Refer to Maintenance, Charging The System.
  28.  

4.0L Engine



Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


CAUTION
Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions may result in serious or fatal injury.


NOTE
The A/C compressor may be removed and repositioned without discharging the refrigerant system or disconnecting the refrigerant lines.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Recover the refrigerant from the refrigerant system. Refer to Maintenance, Discharging The System.
  6.  
  7. Remove the nuts (2 and 4) that secure the A/C discharge line (1) and the A/C suction line (5) to the A/C compressor (3).
  8.  
  9. Disconnect the A/C discharge and suction lines from the A/C compressor and remove and discard the O-ring seals and gaskets

    Click image to see an enlarged view

    Fig. Remove the A/C discharge and suction lines-4.0L engine

  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Remove the splash shield from the right side frame rail.
  14.  
  15. Remove the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  16.  
  17. Disconnect the wire harness connector from the A/C compressor clutch coil.
  18.  
  19. Remove the 1 bolt (2) and 2 nuts (3) that secure the A/C compressor to the engine.
  20.  
  21. Remove the A/C compressor from the engine compartment.
  22.  
  23. Install plugs or tape to seal the opened refrigerant line fittings and compressor ports.

    Click image to see an enlarged view

    Fig. Remove the A/C compressor from the engine compartment-4.0L engine

  24.  

To install:


WARNING
If the A/C compressor is being replaced, be certain to adjust the refrigerant system oil level. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.


WARNING
The A/C receiver/drier must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C receiver/drier can cause serious damage to the replacement A/C compressor.


NOTE
When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be removed from the new A/C compressor.


NOTE
Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets may 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 the oil in the new A/C compressor must be drained. Finally, the new compressor must be refilled with the same amount of new refrigerant oil that was drained out of the old compressor. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

    Click image to see an enlarged view

    Fig. Refrigerant Oil Capacities Chart

  2.  
  3. Position the A/C compressor onto the engine.
  4.  
  5. Install and tighten the bolt (2) and nuts (3) in the following sequence:
    1. Install the bolt and hand tighten.
    2.  
    3. Install the nuts and hand tighten.
    4.  
    5. Tightened the upper nut to 17 ft. lbs. (23 Nm).
    6.  
    7. Tightened the lower nut to 17 ft. lbs. (23 Nm).
    8.  
    9. Tightened the rear bolt to 17 ft. lbs. (23 Nm).
    10.  

  6.  
  7. Connect the wire harness connector to the A/C compressor clutch coil.
  8.  
  9. Install the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  10.  
  11. Install the splash shield onto the right side frame rail.
  12.  
  13. Lower the vehicle.
  14.  
  15. Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.
  16.  
  17. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and the new gaskets onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  18.  
  19. Install the A/C discharge line (1) and the A/C suction line (5) onto the A/C compressor (3).
  20.  
  21. Install the nuts (2 and 4) that secure the A/C discharge and suction lines to the A/C compressor. Tighten the nuts to 17 ft. lbs. (23 Nm).
  22.  
  23. Reconnect the negative battery cable and tighten the nut to 45 inch lbs. (5 Nm).
  24.  
  25. Evacuate the refrigerant system. Refer to Maintenance, Evacuating The System.
  26.  
  27. Charge the refrigerant system. Refer to Maintenance, Charging The System.
  28.  

 
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