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A/C Compressor Failure (24-005-03)

Publication date: 2004-06-01
Reference number: 24-005-03
Supersedes refnos: 24-004-04

A/C COMPRESSOR FAILURE

A/C COMPRESSOR FAILURE

TECHNICAL SERVICE BULLETIN

Reference Number(s): 24-004-04, Date of Issue:  June 1, 2004
GROUP: Heating & A/C
Superceded Bulletin(s): 24-005-03, Date of Issue:  June 20, 2003
NOTE: THIS BULLETIN SUPERSEDES SERVICE BULLETIN 24-005-03, DATED JUNE 20, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES CORRECTED PART NUMBERS.

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

  1. 2001-2003 (RS) Town & Country/Caravan/Voyager
  2. 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.

PARTS REQUIRED

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 Ib.) Cylinder (Each 30 Ib. cylinder will service (Each 30 Ib. cylinder will service
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

EQUIPMENT REQUIRED

Part No. Description
NPN Refrigerant Recovery/Recycling Station - Models Available hrough 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.
  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.
  14. Disconnect the right side wiper module drain tube and relocate it to gain access to the expansion valve (Fig 1 ).
    Fig 1: Equipment Required
    G00232884
  15. Disconnect the suction line from the expansion valve tapping plate.
  16. Disconnect the suction line from the A/C compressor.
  17. Disconnect the discharge line from the A/C compressor (Fig 2 ).
    Fig 2: Discharge Line At Compressor
    G00232885
  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.
  20. Accessing the fastener through the headlamp opening, disconnect the discharge line from the condenser (Fig 3 )
    Fig 3: Discharge Line At Condenser
    G00232886
  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.
  25. Disconnect the clutch coil connector at the A/C compressor (Fig 4 )
    Fig 4: Compressor Assembly
    G00232887
  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.
  28. Remove the tie strap on the liquid/suction lines (Fig 5 ).
    Fig 5: Underbody Connections
    G00232888
  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.
    NOTE: 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.
  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 Receiver/Drier
    G00232889
  37. Using a hacksaw, cut the outside circumference of the receiver/drier case.
  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
    G00232890
  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 REPAIR PROCEDURE 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.
  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
    G00232891
  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.
  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
    G00232892
  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 ).
    Fig 10: Rear Heater-A/C Mounting Studs
    G00232893
  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.
  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
    G00232894
  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.
  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
    G00232895
  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.
    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
    G00232896
  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.
  4. Add the following amount of additional oil to the A/C compressor:
    1. Dual A/C units add 80 ml (2.7 oz.).
    2. 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
    G00232897
  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.
  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. 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.).
  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
    G00232898
    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.).
  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(R).
    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
    G00183681
  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
    G00183682

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

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.
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.
08-19-37-97 Reprogram Powertrain Control Module 0.5 Hrs.
08-19-37-98 PCM Update Previously Performed 0.2 Hrs.

FAILURE CODE

FAILURE CODE

Code Description
YR A/C Performance
FM Flash Module
P9 Inspection
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