My AC is working fine and then it just stop Mechanic told me it's The AC evaporator how can I tell if it is 100% don't want to do the job for no reason and is there any way of repairing it without taking out the whole –dash ?

 

Here is some information that may help.


SUBJECT:
A/C Compressor Failure
OVERVIEW:
This bulletin involves replacing the A/C compressor, related lines, inspecting the
receiver/drier, and checking the Powertrain Control Module (PCM) to ensure the
appropriate level software is installed.
NOTE: THE A/C COMPRESSOR WARRANTY PERIOD HAS BEEN EXTENDED TO 7
YEARS OR 70,000 MILES. REFER TO WARRANTY BULLETIN D-03-12 FOR
COMPLETE DETAILS.
MODELS:
2001 - 2003 (RS) Town & Country/Caravan/Voyager
2001 - 2003 (RG) Chrysler Voyager (International Markets)
NOTE: THIS BULLETIN APPLIES TO RS VEHICLES EQUIPPED WITH A 3.3L OR 3.8L
ENGINE (SALES CODE EGA, EGH, OR EGM) AND A SINGLE A/C SYSTEM
(SALES CODE HAA OR HAD) BUILT ON OR BEFORE FEBRUARY 23, 2003
(MDH 0223XX) OR A DUAL A/C SYSTEM (SALES CODE HBB) BUILT ON OR
BEFORE APRIL 1, 2003 (MDH 0401XX) AND RG VEHICLES EQUIPPED WITH
A 3.3L ENGINE (SALES CODE EGA) AND A SINGLE A/C SYSTEM (SALES
CODE HAA, HAD, OR HAJ) BUILT ON OR BEFORE APRIL 7, 2003 (MDH
0407XX) OR A DUAL A/C SYSTEM (SALES CODE HAH) BUILT ON OR
BEFORE MAY 27, 2003 (MDH 0527XX).
SYMPTOM/CONDITION:
Vehicle operator may describe that the A/C system is inoperative.
Technician may find the A/C compressor has failed due to lack of lubrication.
DIAGNOSIS:
If the A/C compressor fails due to lack of lubrication, perform the Repair Procedure.
NUMBER: 24-004-04
GROUP: Heating & A/C
DATE: June 1, 2004
PARTS REQUIRED:
Qty. Part No. Description
AR (1) 05135003AA A/C Package (Single Air)
Package Contains:
1 - 05005440AF Compressor, A/C
1 - 04677492AA Line, A/C Discharge
1 - 05066503AB Drier, Receiver
1 - 05011590AA O Ring, A/C Line
1 - 04882137 O Ring, A/C Line
1 - 05066498AA Gasket & O Ring Kit
AR (1) 05135004AA A/C Package (Dual Air)
Package Contains:
1 - 05005441AG Compressor, A/C
1 - 04677492AA Line, A/C Discharge
1 - 05005243AD Line A/C Suction
1 - 05066503AB Drier, Receiver
1 - 04882137 O Ring, A/C Line
1 - 05011590AA O Ring, A/C Line
AR (1) 05135005AA O Ring Package, A/C
Package Contains:
1 - 04885802AA O Ring, Exp.Valve
1 - 04885803AA O Ring, Exp.Valve
1 - 05066504AA O Ring, A/C Line
1 - 04882137 O Ring, A/C Line
1 - 04882136 O Ring, A/C Suction
AR 82300101 R-134A Refrigerant 13.6 kg (30 lb.) Cylinder
(Each 30 lb. cylinder will service
approximately 12 vehicles)
AR 82300102 A/C Compressor Oil (250 ml / 8.4 oz.) (Each
bottle will service two vehicles).
AR (1) 04669020 Authorized Software Update Label
AR (1) 04275086AB Authorized Modification Label
EQUIPMENT REQUIRED:
NPN Refrigerant Recovery/Recycling Station - Models Available
through Pentastar Service Equipment
REPAIR PROCEDURE A:
A/C Compressor, Discharge/Suction Lines and Receiver/Drier Replacement.
NOTE: VEHICLES EQUIPPED WITH SINGLE A/C SYSTEM DO NOT REQUIRE
SUCTION LINE REPLACEMENT.
1. Open the hood.
2. Vehicles equipped with single A/C system proceed to step 8. Vehicles equipped with
dual A/C system proceed to next step.
24-004-04 -2-
3. Remove the Fuel Pump relay from the Power Distribution Center (PDC). For location
of the relay, refer to the label on the underside of the PDC cover.
4. Start and run the engine until it stalls.
5. Attempt to restart the engine until it will no longer run.
6. Turn the ignition key to the "OFF" position.
7. Install the fuel pump relay to the PDC.
8. Disconnect the negative battery cable.
9. Remove the air cleaner assembly to gain access to the A/C liquid and suction lines.
10. Using an approved A/C refrigerant recovery machine, evacuate the A/C system of all
R-134a refrigerant.
NOTE: FOLLOW INSTRUCTIONS SUPPLIED WITH THE A/C RECOVERY
EQUIPMENT.
WARNING:THE AIR CONDITIONING SYSTEM CONTAINS REFRIGERANT UNDER
HIGH PRESSURE. SEVERE PERSONAL INJURY MAY RESULT FROM
IMPROPER SERVICE PROCEDURES. ALWAYS WEAR EYE PROTECTION
WHEN SERVICING THE AIR CONDITIONING REFRIGERANT SYSTEM.
11. Disconnect both liquid lines from the receiver/drier.
NOTE: CLEAN THE TOP OF THE RECEIVER/DRIER BEFORE REMOVING THE
LIQUID LINES.
CAUTION: SOME RESIDUAL SYSTEM PRESSURE MAY BE PRESENT WHEN
REMOVING THE LIQUID LINES FROM THE RECEIVER/DRIER. AVOID
BREATHING THE REFRIGERANT AND/OR REFRIGERANT OIL
VAPOR/MIST.
12. Remove the receiver/drier by sliding the receiver/drier from the mounting bracket.
Save the receiver/drier for later inspection.
13. Vehicles with dual A/C system, proceed to next step. Vehicles with single A/C system,
proceed to step 16.
-3- 24-004-04
14. Disconnect the right side wiper module drain tube and relocate it to gain access to the
expansion valve (Fig. 1).
Fig. 1 RIGHT WIPER MODULE DRAIN TUBE
1 - RIGHT FRONT STRUT TOWER
2 -A/C PRESSURE TRANSDUCER CONNECTOR
3 - RIGHT WIPER MODULE DRAIN TUBE
4 - LIQUID LINE
15. Disconnect the suction line from the expansion valve tapping plate.
16. Disconnect the suction line from the A/C compressor.
24-004-04 -4-
17. Disconnect the discharge line from the A/C compressor (Fig. 2).
Fig. 2 DISCHARGE LINE AT COMPRESSOR
1 - DISCHARGE LINE
2 - NUT
3 - DISCHARGE LINE FITTING
4 - STUD
5 - DISCHARGE PORT
18. RS vehicles proceed to next step. RG vehicles proceed to step 22.
NOTE: RG VEHICLES DO NOT USE THE NEW DISCHARGE LINE INCLUDED IN THE
PARTS KIT. DISCARD THE NEW DISCHARGE LINE.
19. Remove the right side (passenger side) headlamp assembly.
-5- 24-004-04
20. Accessing the fastener through the headlamp opening, disconnect the discharge line
from the condenser (Fig. 3)
Fig. 3 DISCHARGE LINE AT CONDENSER
1 - CONDENSER
2 - DISCHARGE LINE FITTING
3 - LIQUID LINE FITTING
4 - NUT
21. Remove and discard the discharge line from the vehicle.
22. Lift the vehicle on an appropriate hoist.
23. Remove the right side (passenger side) lower wheel opening splash shield.
24. Remove the serpentine drive belt.
24-004-04 -6-
25. Disconnect the clutch coil connector at the A/C compressor (Fig. 4)
Fig. 4 COMPRESSOR ASSEMBLY
1 - STUD
2 - CLUTCH COIL CONNECTOR
3 - DISCHARGE PORT
4 - SCREW
5 - SUCTION PORT
6 - COMPRESSOR
7 - SCREW
8 - NUT
26. Remove the A/C compressor from the vehicle and set the compressor aside (Fig. 4).
NOTE: AVOID SPILLING ANY COMPRESSOR OIL DURING REMOVAL. THE OIL WILL
NEED TO BE MEASURED TO ENSURE THE CORRECT AMOUNT OF OIL IS
ADDED TO THE NEW COMPRESSOR.
27. Vehicles with single A/C system, proceed to step 29. Vehicle with dual A/C system,
proceed to next step.
-7- 24-004-04
28. Remove the tie strap on the liquid/suction lines (Fig. 5).
Fig. 5 UNDERBODY CONNECTIONS
1 - SUCTION LINE
2 - LIQUID LINE EXTENSION
3 - TIE STRAP
4 - HEATER LINE EXTENSIONS
5 - UNDERBODY LIQUID LINE
29. Separate the front suction line extension from the rear underbody suction line (Fig. 5).
30. Lower the vehicle.
31. Vehicles with single A/C system, proceed to step 35. Vehicle with dual A/C system,
proceed to next step.
32. Disconnect the fuel line quick connect at the fuel rail.
33. Remove and discard the suction line.
CAUTION: NOTE THE SUCTION HOSE ROUTING TO THE REAR A/C UNIT BEFORE
REMOVING THE SUCTION LINE.
34. Place the new suction line into position.
35. Inspect the receiver/drier previously removed as follows.
24-004-04 -8-
36. Using a tape measure, measure down from the top (port side) of the receiver/drier
120.6 mm (4.75 in.) and mark the receiver/drier as shown in (Fig. 6).
Fig. 6 OPENING THE RECEIVER/DRIER
1 - RECEIVER/DRIER ASSEMBLY
2 - MEASURE DOWN FROM TOP
3 - TAPE MEASURE
4 - RECEIVER/DRIER PORTS
37. Using a hacksaw, cut the outside circumference of the receiver/drier case.
-9- 24-004-04
38. Inspect inside the receiver/drier for the presence of desiccant powder. Desiccant in
this section of the receiver/drier is an indication that desiccant has been released into
the A/C system (Fig. 7).
Fig. 7 RECEIVER/DRIER CUT OPEN
1 - RECEIVER/DRIER CUT OPEN
2 - CHECK FOR DESICCANT POWDER INSIDE
39. If desiccant has been released into the A/C system, continue with Section B -
“Removing Desiccant Contamination from the A/C System”. If desiccant has not been
released into the A/C system, continue with Section C - “Compressor Installation”.
REPAIR PROCEDURE B:
Removing Desiccant Contamination from the A/C System.
NOTE: O-RING PACKAGE **05135005AA** IS REQUIRED TO RESEAL THE
EXPANSION VALVE(S).
1. Vehicles with dual A/C system, proceed to step 3. Vehicle with single A/C system,
proceed to next step.
2. Disconnect the suction and liquid line from the expansion valve.
24-004-04 -10-
3. Remove the two expansion valve retaining screws and remove the expansion valve
from the evaporator tube tapping plate (Fig. 8).
Fig. 8 REMOVING EXPANSION VALVE
1 - EXPANSION VALVE
2 - EXPANSION VALVE ELECTRICAL CONNECTOR
3 - EXPANSION VALVE RETAINING SCREWS
4 - RIGHT FRONT STRUT TOWER
4. Disconnect the expansion valve electrical connector (Fig. 8).
5. Using needle nose pliers, remove the refrigerant diverter located in the liquid line port
of the evaporator.
6. Using clean compressed air, back flush the evaporator by blowing air into the suction
port of the evaporator.
7. Install the refrigerant diverter into the liquid line port of the evaporator.
8. Using clean compressed air, blow out any desiccant from the expansion valve.
9. Install new o-rings, from o-ring package (p/n **05135005AA**), onto the evaporator
fittings by the tapping plate.
10. Connect the electrical connector to the expansion valve and place the expansion valve
onto the evaporator tapping plate fitting. Install the retaining screws and tighten the
screws to 11 Nm (97 in. lbs.).
11. RS vehicles proceed to next step. RG vehicles, cover the compressor end of the
discharge line with a clean shop towel. Using clean compressed air, blow into the
receiver/drier end of the discharge line, through the condenser, catching any
contamination at the compressor end of the discharge line.
12. Vehicles with dual A/C system, proceed to step 14. Vehicle with single A/C system,
replace the o-ring on the liquid line and suction line and install the lines to the
expansion valve. Tighten the retaining nut to 23 Nm (17 ft. lbs.).
13. Vehicles with single A/C system, proceed to Repair Procedure C - Compressor
Installation.
14. Remove the rear seat from the vehicle.
-11- 24-004-04
15. Remove the upper and lower scuff panels on the rear lift gate opening.
16. Remove the right side sliding door sill plate.
17. Remove the right rear "D" pillar trim panel.
18. Remove the interior right side quarter trim panel to gain access to the rear heater-A/C
unit.
19. Remove the upper and lower air ducts from the rear heater-A/C unit housing.
20. Remove the rear heater-A/C unit housing mounting bolts and strap (Fig. 9).
Fig. 9 REAR HEATER-A/C UNIT
1 - REAR HEATER-A/C UNIT HOUSING
2 - MOUNTING BOLT
3 - MOUNTING BOLT
4 - STUD
5 - HEATER LINES
6 - HOUSING TO FLOOR MOUNTING NUTS
21. Raise the vehicle on the hoist.
22. Remove the rear heater-A/C unit housing floor mounting nuts from the mounting studs
(Fig. 9) and(Fig. 10).
24-004-04 -12-
Fig. 10 REAR HEATER-A/C MOUNTING STUDS
1 - MOUNTING STUDS (3)
23. Remove the liquid and suction lines from the rear heater A/C unit housing tapping
plate located under the vehicle.
CAUTION: CLEAN THE AREA OF ANY MUD OR DIRT TO PREVENT DEBRIS FROM
FALLING INTO THE A/C LINES.
24. Lower the vehicle.
25. Using clamp-off pliers, clamp-off the two heater hoses at the rear heater-A/C unit
housing and disconnect the heater hoses from the rear heater core.
NOTE: PLACE A SHOP TOWEL UNDER THE HEATER HOSE CONNECTIONS TO
CATCH ANY COOLANT THAT MIGHT SPILL.
26. Disconnect the electrical connections on the rear heater-A/C unit housing.
27. Remove the rear heater-A/C unit from the vehicle.
-13- 24-004-04
28. Remove the liquid and suction line access panel retaining screw and then remove the
panel (Fig. 11)
Fig. 11 REAR A/C UNIT EXPANSION VALVE
1 - ACCESS PANEL RETAINING SCREW
2 - SUCTION AND LIQUID LINE ACCESS PANEL
3 - EXPANSION VALVE
29. Remove and save the insulating wrap from the expansion valve.
30. Remove the suction/liquid line retaining nut and bracket at the expansion valve and
remove the lines.
24-004-04 -14-
31. Remove the two (2) expansion valve mounting screws and remove the expansion
valve from the evaporator tube tapping plate (Fig. 12).
Fig. 12 EXPANSION VALVE RETAINING SCREWS
1 - EXPANSION VALVE
2- EXPANSION VALVE RETAINING SCREWS
3 - EVAPORATOR TUBE TAPPING PLATE
32. Using clean compressed air, clean the expansion valve by blowing out any desiccant
from the expansion valve, evaporator and the suction and liquid lines.
33. Install new o-rings onto the evaporator fittings and install the expansion valve onto the
evaporator fittings. Tighten the retaining screws to 11 Nm (97 in. lbs.) (Fig. 12).
34. Install new o-rings on the suction line and liquid line.
35. Install the suction line, liquid line and the retaining bracket and nut. Tighten the
retaining nut to 23 Nm (17 ft. lbs.).
36. Install the liquid and suction line access panel into position and insert the retaining
screw. Tighten the screw to 2 Nm (18 in. lbs.).
37. Install the insulating wrap onto the expansion valve.
38. Install the rear heater-A/C unit housing into position and install retaining strap and
mounting bolts.
39. Connect the heater hoses and remove the clamp-off pliers.
40. Connect the electrical connectors to the rear heater-A/C unit housing.
41. Install upper and lower air ducts.
42. Install the quarter trim panel.
43. Install the "D" pillar trim panel.
44. Install the upper and lower lift gate opening scuff panels.
45. Install the right side sliding door sill plate.
46. Install the rear seat.
47. Lift the vehicle on the hoist and install the housing mounting nuts (Fig. 10).
48. Using clean compressed air, blow out the liquid and suction lines at the rear
heater-A/C unit housing.
-15- 24-004-04
NOTE: THE FORWARD END OF THE LIQUID LINE MUST BE POINTED AWAY FROM
THE FRONT EXPANSION VALVE BEFORE BLOWING OUT THE LIQUID LINE.
THIS WILL KEEP CONTAMINATION FROM BEING BLOWN AT THE FRONT
EXPANSION VALVE.
49. Install new o-rings on the liquid and suction lines.
50. Connect the liquid and suction lines to the rear heater-A/C unit housing tapping plate.
51. Continue with Section C - “Compressor Installation."
REPAIR PROCEDURE C:
Compressor Installation.
1. Measure the amount of oil that is in the old compressor by pouring the old oil out of the
compressor port into a measuring bottle (Fig. 13)
NOTE: DISCARD THE OLD OIL AFTER MEASURING.
Fig. 13 DRAINING NEW COMPRESSOR
1 - A/C COMPRESSOR
2 - A/C COMPRESSOR PORTS
3 - MEASURING BOTTLE
4 - A/C COMPRESSOR OIL
2. Drain and save all of the oil from the new compressor into a clean measuring bottle
(Fig. 13).
3. Using the oil removed from the new compressor, pour the same amount of oil into the
new compressor as was measured from the old compressor.
24-004-04 -16-
4. Add the following amount of additional oil to the A/C compressor:
a. Dual A/C units add 80 ml (2.7 oz.).
b. Single A/C unit add 40 ml (1.4 oz.).
NOTE: IF ADDITIONAL OIL IS REQUIRED USE MOPAR (P/N 82300102) PAG OIL.
CAUTION: REFRIGERANT OIL WILL ABSORB MOISTURE FROM THE ATMOSPHERE
IF LEFT UNCAPPED. DO NOT OPEN THE CONTAINER OF OIL UNTIL YOU
ARE READY TO USE IT.
5. Raise the vehicle on the hoist and install the new compressor onto the engine
mounting bracket. Tighten mounting bolts to 54 Nm (40 ft. lbs.).
6. Connect the compressor electrical connector.
7. Install the serpentine drive belt (Fig. 14).
Fig. 14 SERPENTINE BELT ROUTING
1 - POWER STEERING PUMP PULLEY
2 - BELT TENSIONER PULLEY
3 - IDLER PULLEY
4 - GENERATOR PULLEY
5 - A/C COMPRESSOR PULLEY
6 - DRIVE BELT
7 - WATER PUMP PULLEY
8. Install the right side splash shield.
9. Vehicles with single A/C system, proceed to next step. Vehicle with dual A/C system,
connect the suction lines at the center connection under the vehicle and install the tie
strap (Fig. 5). Tighten the center connection fitting to 23 Nm (17 ft. lbs.).
10. Lower the vehicle.
-17- 24-004-04
11. RG vehicles proceed to next step. RS vehicles install the new discharge line, p/n
04677492AA.
12. Connect the discharge line to the compressor. Tighten the discharge line retaining
nuts to 23 Nm (17 ft. lbs.).
13. RG vehicles proceed to step 15. RS vehicles, connect the other end of the discharge
line to the condenser. Tighten the discharge line retaining nuts to 23 Nm (17 ft. lbs.).
14. Install the right headlamp assembly.
15. Connect the suction line to the compressor. Tighten the suction line retaining nuts to
23 Nm (17 ft. lbs.).
16. Vehicles with single A/C system, proceed to next step. Vehicles with dual A/C system,
replace the o-ring on the liquid line and then install the liquid line and suction line to
the expansion valve. Tighten the retaining nut to 23 Nm (17 ft. lbs.).
17. Add an additional 30 ml (1 oz.) of oil (P/N 82300102) to the center port of the new
receiver/drier and install the receiver/drier into the mounting bracket.
18. Install new o-rings onto the liquid line ends that connect to the receiver/drier.
19. Connect the liquid lines to the receiver/drier ports. Tighten the mounting bolts to 2 Nm
(18 in. lbs.).
20. Vehicles with single A/C system, proceed to next step. Vehicle with dual A/C system,
connect the right side wiper module drain hose (Fig. 1).
21. Connect an appropriate A/C machine (that meets SAE standard J2210) to the A/C
system (Fig. 15). Evacuate the system for 15 minutes.
Fig. 15 TYPICAL A/C MACHINE
NOTE: FOLLOW THE A/C MACHINE MANUFACTURER'S OPERATING
INSTRUCTIONS TO EVACUATE THE SYSTEM.
22. Vehicles with single A/C system, proceed to next step. Vehicle with dual A/C system,
connect the fuel line to the fuel rail.
23. Install the air cleaner assembly.
24. Connect the negative battery cable to the battery terminal. Tighten the battery terminal
fastener to 8.5 Nm (75 in. lbs.).
24-004-04 -18-
25. Using an appropriate A/C machine, install R-134a refrigerant into the A/C system
(Refer to the underhood label for the correct charge amount).
26. Verify A/C system operation and continue with Section D - “Check and Reprogram the
PCM If Necessary."
REPAIR PROCEDURE D:
Check and Reprogram the PCM If Necessary.
1. Verify the PCM has the latest software revision level. If PCM is at the latest revision,
no further action is necessary. If PCM is not at the latest revision level, proceed to next
step.
2. Flash the controller using the TechCONNECT/MDS2 and DRBIII®.
NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN
OTHER MODULES (TCM, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF
SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL
DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE
THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE
FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE
TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL
OTHER MODULES HAVE HAD THEIR FAULTS ERASED.
NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW.
3. Type the necessary information on the “Authorized Software Update Label” p/n
04669020 (Fig. 16). Attach the label to the PCM and cover the label with the clear
plastic overlay.
Fig. 16 AUTHORIZED SOFTWARE UPDATE LABEL
-19- 24-004-04
4. Type the necessary information on the “Authorized Modification Label” p/n
04275086AB and attach near the VECI label (Fig. 17).
Fig. 17 AUTHORIZED MODIFICATION LABEL
1 - POWERTRAIN CONTROL MODULE P/N (INSERT P/N) USED
2 - CHANGE AUTHORITY: TSB XX-XXX-XX
3 - DEALER CODE: XXXXX
4 - DATE: XX-XX-XX
POLICY:
Reimbursable within the provisions of the extended warranty period of 7 years or 70,000
miles. Refer to Warranty Bulletin D-03-12 for complete details.
TIME ALLOWANCE:
Labor Operation
No:
Description Amount
24-10-02-90 Replace A/C Compressor, and Hoses (Single A/C
Unit)
1.2 Hrs.
24-10-02-91 Replace A/C Compressor, and Hoses (Dual A/C
Unit)
1.7 Hrs.
Related Operations:
24-10-02-92 Clean Out Desiccant from A/C System (Single
A/C Unit)
0.3 Hrs.
24-10-02-93 Clean Out Desiccant from A/C System (Dual A/C
Unit)
1.3 Hrs.