PT Cruiser, 2001 - 2005

Compressor

Print

Removal & Installation



  1. Disconnect and isolate the battery negative cable.
  2.  
  3. Recover the refrigerant from the refrigerant system.
  4.  
  5. Remove the serpentine drive belt.
  6.  
  7. Raise and support the vehicle.
  8.  
  9. Disconnect the engine wire harness connectors from the compressor clutch coil connector and the high pressure cut out switch (.
  10.  
  11. Remove the bolt that secures the suction line to the A/C compressor.
  12.  
  13. Disconnect the suction line from the A/C compressor suction port.
  14.  
  15. Remove the rubber O-ring seal from the suction line fitting discard.
  16.  
  17. Install plugs in, or tape over the opened A/C compressor suction port and the suction line fitting.
  18.  
  19. Remove the bolt that secures the discharge line to the A/C compressor.
  20.  
  21. Disconnect the discharge line from the A/C compressor discharge port.
  22.  
  23. Remove the rubber O-ring seal from the discharge line fitting and discard.
  24.  
  25. Install plugs in, or tape over the opened A/C compressor discharge port and the discharge line fitting.
  26.  
  27. Support the A/C compressor and remove the four A/C compressor mounting bolts.
  28.  
  29. Remove the A/C compressor from the engine compartment.

    Click image to see an enlarged view

    Fig. The A/C compressor mounting point

  30.  

To install:


NOTE
If a replacement compressor is being installed, be certain to check the refrigerant oil level. Use only refrigerant oil of the type recommended for the compressor in the vehicle.



Click image to see an enlarged view

Fig. The A/C compressor refrigerant lines

  1. Position the A/C compressor into the engine compartment.
  2.  
  3. Install the four bolts that secure the A/C compressor to the mounting bracket. Tighten the bolts to 21 ft. lbs (28.3 Nm.).
  4.  
  5. Remove the tape or plugs from the A/C compressor discharge port and the discharge line fitting.
  6.  
  7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the discharge line fitting. 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.
  8.  
  9. Reconnect the discharge line fitting to the A/C compressor discharge port.
  10.  
  11. Install the bolt that secures the discharge line fitting to the A/C compressor. Tighten the bolt to 108 inch lbs. (12.2 Nm).
  12.  
  13. Remove the tape or plugs from the A/C compressor suction port and the suction line fitting.
  14.  
  15. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the suction line fitting. 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. Reconnect the suction line fitting to the A/C compressor suction port.
  16.  
  17. Install the bolt that secures the suction line fitting to the A/C compressor. Tighten the bolt to 108 inch lbs. (12.2 Nm).
  18.  
  19. Reconnect the engine wire harness connectors to the compressor clutch coil connector and the high pressure cut out switch.
  20.  
  21. Lower the vehicle.
  22.  
  23. Install the accessory drive belt.
  24.  
  25. Reconnect the battery negative cable.
  26.  
  27. Evacuate the refrigerant system.
  28.  
  29. Charge the refrigerant system.
  30.  

1.6L Engine
  1. Disconnect negative battery cable.
  2.  
  3. Disconnect positive battery cable.
  4.  
  5. Remove battery.
  6.  
  7. Partially drain cooling system.
  8.  
  9. Disconnect coolant temperature sensor electrical connector.
  10.  
  11. Remove coolant temperature sensor.
  12.  

To install:

  1. Install coolant temperature sensor. Tighten sensor to 17 Nm (150 inch lbs.).
  2.  
  3. Reconnect coolant temperature sensor connector.
  4.  
  5. Install battery.
  6.  
  7. Connect positive and negative battery cables.
  8.  
  9. Fill cooling system.
  10.  

2.0L & 2.4L
  1. Remove the air cleaner lid and makeup air hose.
  2.  
  3. Remove the negative battery cable.
  4.  
  5. With the engine cold, drain coolant until level drops below sensor level.
  6.  
  7. Disconnect coolant sensor electrical connector.
  8.  
  9. Remove coolant sensor.
  10.  

To install:

  1. Install coolant sensor. Tighten sensor to 17-21 Nm (12-16 ft. lbs.) torque.
  2.  
  3. Attach electrical connector to sensor.
  4.  
  5. Fill cooling system.
  6.  
  7. Install the negative battery cable.
  8.  
  9. Install the air cleaner lid and makeup air hose.
  10.  

Non-Turbo Models
  1. Disconnect negative battery cable.
  2.  
  3. Partially drain cooling system below level of Engine Coolant Temperature (ECT) sensor.
  4.  
  5. Disconnect the ECT sensor electrical connector.
  6.  
  7. Remove ECT sensor.

    Click image to see an enlarged view

    Fig. Location of the Engine Coolant Temperature (ECT) sensor-Non-Turbo models

  8.  

To install:

  1. Install ECT sensor. Torque sensor to 168 inch lbs. (19 Nm).
  2.  
  3. Reconnect ECT sensor electrical connector.
  4.  
  5. Fill cooling system.
  6.  
  7. Connect negative battery cable.
  8.  

Turbo Models
  1. Disconnect negative battery cable.
  2.  
  3. Partially drain cooling system below level of ECT Sensor.
  4.  
  5. Remove upper torque strut.
  6.  
  7. Disconnect ECT sensor electrical connector.
  8.  
  9. Remove ECT sensor.

    Click image to see an enlarged view

    Fig. Location of the Engine Coolant Temperature (ECT) sensor- turbo models

  10.  

To install:

  1. Install ECT sensor. Torque sensor to 168 inch lbs. (19 Nm).
  2.  
  3. Reconnect ECT sensor electrical connector.
  4.  
  5. Install upper torque strut.
  6.  
  7. Fill cooling system.
  8.  
  9. Connect negative battery cable.
  10.  

 
label.common.footer.alt.autozoneLogo