TownAndCountry 2008

Removal & Installation

Print


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.

  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 grille.
    1. On Dodge vehicles:

      Remove the upper grille fasteners and push pins
       
      Remove the emblem from the grille
       
      Unclip the inserts from the fascia
       
      Remove the grille insert from the fascia and vehicle
       

    2.  
    3. On Chrysler vehicles:

      Release the hood latch and open the hood
       
      Raise and safely support the vehicle
       
      Remove the front wheelhouse splash shields fasteners (6 and 7) as necessary to gain access to the bolts attaching the front fascia to the fender (5)
       
      Remove the 2 bolts (4) and 2 push pins (3) attaching the fascia to the upper core support
       
      Remove the push pins attaching the fascia to the lower support
       
      Disconnect the fog lamp wire connectors, if necessary
       
      Disconnect the electrical wiring harness, if equipped, at the front rail support
       
      Lower the vehicle
       
      Remove the grille/bumper fascia (1) from the vehicle

      Click image to see an enlarged view

      Fig. Removing the front grille/bumper fascia from the vehicle-Chrysler vehicles

       

    4.  

  8.  
  9. Remove the nuts (3) that secure the A/C discharge line (1) and the A/C liquid line (4) to the condenser tapping block (2) located in the right front corner of the engine compartment.
  10.  
  11. Disconnect the A/C discharge and liquid lines from the condenser tapping block and remove and discard the O-ring seals and gaskets.
  12.  
  13. Install plugs or tape to seal the opened refrigerant line fittings and condenser ports.
  14.  
  15. Remove the screw (5) that secures the condenser tapping block to the radiator (6).

    Click image to see an enlarged view

    Fig. Disconnect the A/C discharge and liquid lines from the condenser tapping block

  16.  
  17. Disconnect the transaxle cooler lines from the transaxle fluid cooler.
  18.  
  19. Install plugs or tape to seal the opened transaxle fluid cooler ports.
  20.  
  21. Remove the upper radiator crossmember (2) and position it out of the way.

    Click image to see an enlarged view

    Fig. Remove the upper radiator crossmember (2) and position it out of the way

  22.  
  23. Disengage the retaining tabs (4) that secure the upper condenser mounting brackets (3) to the radiator.
  24.  
  25. Carefully push the radiator rearward for clearance.
    NOTE
    Be certain to note the location of each of the radiator and condenser air seals prior to removal of the A/C condenser. These air seals must be properly installed for the A/C and engine cooling systems to perform as designed.

  26.  
  27. Lift the A/C condenser (5) straight upward to disengage the lower condenser mounting brackets from the radiator and remove the condenser from the engine compartment.

    Click image to see an enlarged view

    Fig. Remove the A/C condenser from the engine compartment

  28.  

To install:


WARNING
Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. 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
Any factory-installed air seals or shrouds must be properly reinstalled when servicing the A/C condenser. Failure to follow this caution may result in the A/C and engine cooling systems not operating to design standards and possible engine and transaxle damage due to overheating.


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
If only the A/C condenser is being replaced, add 1 fluid ounce (30 milliliters) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.


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.


NOTE
Be certain that each of the radiator and condenser air seals are installed in their proper locations.

  1. Carefully push the radiator rearward for clearance.
  2.  
  3. Position the A/C condenser (5) into the front of the engine compartment and engage the lower condenser mounting brackets to the radiator.
  4.  
  5. Engage the retaining tabs (4) that secure the upper condenser mounting brackets (3) to the radiator.
  6.  
  7. Install the upper radiator crossmember (1). Tighten the crossmember bolts to 14 ft. lbs. (19 Nm).
  8.  
  9. Remove the plugs or tape from the opened transaxle fluid cooler ports.
  10.  
  11. Connect the transaxle cooler lines (2) to the transaxle fluid cooler .
  12.  
  13. Install the screw (5) that secures the condenser tapping block (2) to the radiator (6). Tighten the screw securely.
  14.  
  15. Remove the tape or plugs from the opened refrigerant line fittings and condenser ports.
  16.  
  17. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and the new gaskets onto the opened 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. Connect the A/C discharge line (1) and the A/C liquid line (4) to the condenser tapping block.
  20.  
  21. Install the nuts (3) that secure the A/C discharge and liquid lines to the condenser tapping block. Tighten the nuts to 17 ft. lbs. (23 Nm).
  22.  
  23. Install the grille.
  24.  
  25. Reconnect the negative battery cable and tighten the nut to 45 inch lbs. (5 Nm).
  26.  
  27. Evacuate the refrigerant system. Refer to Maintenance, Evacuating The System.
  28.  
  29. If the A/C condenser is being replaced, add 1 fluid ounce (30 milliliters) of refrigerant oil to the refrigerant system. 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.
  30.  
  31. Charge the refrigerant system. Refer to Maintenance, Charging The System.

    Click image to see an enlarged view

    Fig. Refrigerant Oil Capacities Chart

  32.  

 
label.common.footer.alt.autozoneLogo