How to Replace the AC Compressor in a 1993 Dodge Grand Caravan

Replacing an air conditioning compressor on a 1993 Dodge Grand Caravan requires the use of a reclaimer--a machine that captures the Freon, filters out the contaminants and recharges the system. It is not only illegal to vent Freon to the atmosphere, but doing so is also harmful to the environment. The reclaimer should also have a vacuum pump. An air conditioning system must be evacuated of air and moisture in preparation to be recharged.

Things You'll Need

• Air conditioning reclaimer
• Set of wrenches
• Set of 3/8-inch drive sockets
• 3/8-inch drive ratchet
• 3/8-inch Allen wrench
• Can of refrigerant oil

Instructions

1. Hook up the reclaimer to the air conditioning system by attaching the red (high side) hose to the small high pressure line and the blue (low side) line to the largest of the two lines, which is the suction side. Plug the machine in, open the valve to the capture tank in the rear of the machine, turn the machine on, and open both low- and high-side valves. Push the button to reclaim and the machine will begin to remove the Freon.

2. Remove the serpentine belt while the system is being discharged. Use a wrench to take the tension off of the belt. Put the wrench on the tensioner, pull it in toward the center of the engine and release the pressure to remove the belt.

3. Close the low- and high-side valves on the reclaimer. Turn the power off and remove the lines from the vehicle's Schraeder valves. Remove the high- and low-side lines from the compressor using a wrench. Remove the electrical connector from the clutch by pulling it off.

4. Remove the four bolts holding the compressor on the engine, then pull the compressor off the engine.

5. Remove the top manifold from the old compressor using a 3/8-inch drive Allen wrench to remove the four bolts holding it on. Remove the top plate that covers the manifold on the new compressor and fill the manifold with 4 oz. of refrigerant oil.

6. Install the top manifold plate from the old compressor to the new compressor. Tighten the bolts. Turn the center of the compressor shaft by hand 10 revolutions to distribute the oil. Stand the compressor up on end with the clutch down for five minutes so that the oil oils the front seal.

7. Install the compressor and tighten the bolts. Reattach the low- and high-side lines on the compressor manifold using a wrench. Make sure that the lines have new O-rings in place first. Plug in the electrical connector on the clutch mechanism.

8. Install the serpentine belt using the wrench to loosen the tensioner. Attach the low- and high-side reclaimer lines to the manifold on the compressor.

9. Turn the reclaimer on and open both the low- and high-side valves. Push the button for vacuum and set the timer for 15 minutes.

10. Charge the system once the vacuum shows that it is complete by pushing the button for "charge." (Get the charge amount from the sticker on the radiator support shroud and put this number in the reclaimer, then hit the "enter" button). The charge varies with the year and size engine. Most vehicles usually take 1.75 lbs. Once it has charged the system, turn the reclaimer off and remove the reclaimer lines from the compressor.