Dodge Caliber. Manual - part 1435

Lower A/C Suction Line

1. Position the lower A/C suction line (2) into the

engine compartment.

2. Remove the tape or plugs from the suction line fit-

ting and the compressor port.

3. Lubricate a new rubber O-ring seal with clean

refrigerant oil and install it and new gasket onto the
suction line fitting. Use only the specified O-ring as
it is made of a special material for the R-134a sys-
tem. Use only refrigerant oil of the type recom-
mended for the A/C compressor in the vehicle.

4. Connect the lower A/C suction line to the A/C com-

pressor (3).

5. Install the nut (1) that secures the A/C suction line

to the A/C compressor. Tighten the nut to 20 N·m
(15 ft. lbs.).

6. Remove the tape or plugs from the suction line fit-

ting and the accumulator port.

7. Lubricate a new rubber O-ring seal with clean

8. Connect the lower A/C suction line (3) to the A/C

accumulator (1).

9. Install the nut (2) that secures the lower A/C suc-

tion line to the A/C accumulator. Tighten the nut to
5 N·m (44 in. lbs.).

10. Reposition the front of the right front wheel house

splash shield (3) to the body (4) and install the
three push-pin retainers (1) and the three screws
(2). Tighten the screws securely (refer to 23 -
BODY/EXTERIOR/SPLASH

SHIELD-FRONT

WHEELHOUSE - INSTALLATION).

11. Install the right front wheel (refer to 22 - TIRES/

WHEELS - INSTALLATION).

12. Lower the vehicle.

13. Reconnect the negative battery cable.

CAUTION: Do NOT run the engine with a vacuum
pump in operation or with a vacuum present
within the A/C system. Failure to follow this cau-
tion will result in serious A/C compressor damage.

14. Evacuate the refrigerant system (refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -

PLUMBING

24 - 157

STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).

15. Charge the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-

CEDURE - REFRIGERANT SYSTEM CHARGE).

24 - 158

PLUMBING

OIL-A/C REFRIGERANT

DESCRIPTION

The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol (PAG), wax-free
lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils and should never be introduced to an
R-134a refrigerant system.

There are different PAG oils available and each contain a different additive package. Always use only the type of
refrigerant oil recommended for the A/C compressor in the vehicle.

CAUTION: Be certain to check and adjust the refrigerant system oil level when replacing an A/C compressor
(refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE -
REFRIGERANT OIL LEVEL). Failure to properly adjust the refrigerant oil level can prevent the A/C system
from operating as designed and can cause serious A/C compressor damage.

The Denso 5SE12C A/C compressor used in this vehicle is designed to use ND-8 PAG refrigerant oil. Use only this
type of refrigerant oil in the refrigerant system.

OPERATION

After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the
same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compres-
sor damage, and too much can reduce A/C system performance.

PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with,
even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used.
After use, recap the oil container immediately to prevent moisture contamination.

STANDARD PROCEDURE

REFRIGERANT OIL LEVEL

When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free.
After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed
throughout the refrigerant system. The A/C accumulator, A/C evaporator, A/C condenser and the A/C compressor
will each retain a significant amount of the needed refrigerant oil.

It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the
A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling
capacity of the A/C system and consequently result in higher discharge air temperatures.

CAUTION: ND-8 PAG refrigerant oil is used in the Denso 5SE12C A/C compressor. Only refrigerant oil of the
same type should be used to service this R-134a A/C system. Do not use any other refrigerant oil. The
refrigerant oil container should be kept tightly capped until it is ready for use and then tightly capped after
use to prevent contamination from moisture and dirt. Refrigerant oil will quickly absorb any moisture it
comes in contact with, therefore, special effort must be used to keep all R-134a system components mois-
ture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with
the A/C compressor.

NOTE: Most reclaim/recycling equipment will measure the amount of refrigerant oil being removed during
the recovery process. This amount of refrigerant oil should always be added back into the refrigerant sys-
tem. Refer to the reclaim/recycling equipment manufacturers instructions.

It will not be necessary to check the oil level within the A/C refrigerant system or to add oil, unless there has been
an oil loss. A refrigerant oil loss may occur due to component replacement or a rupture or leak from a refrigerant
line, connector fitting, component or component seal. If a leak does occurs, add 30 milliliters (1 fluid ounce) of the
recommended refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be
evident at the leak point by the presence of a wet, shiny surface around the leak.

Refrigerant oil must be added when an A/C accumulator, A/C evaporator or A/C condenser is replaced. Refer to the
Refrigerant Oil Capacities chart.

PLUMBING

24 - 159

REFRIGERANT OIL CAPACITIES

Component

ml.

oz.

Total System Fill

100

3.4

A/C Accumulator

0.7

A/C Condenser

1.0

A/C Evaporator

0.7

A/C Compressor

Drain and measure the oil from the old compressor -
see following text.

CAUTION: Be certain to check and adjust the refrigerant system oil level when replacing an A/C compres-
sor. The refrigerant oil in the Denso 5SE12C A/C compressor can only be drained using the procedure
described below. Failure to properly drain the refrigerant oil from the A/C compressor can prevent the A/C
system from operating as designed and cause serious compressor damage.

When an A/C compressor is replaced, the refrigerant oil must first be drained from the old compressor and mea-
sured. Then the refrigerant oil from the new A/C compressor must be completely drained. Finally, the new A/C com-
pressor must be refilled with the same amount of refrigerant oil that was drained from the old compressor. Use the
following procedure to drain and measure the refrigerant oil in the Denso 5SE12C A/C compressor.

1. Remove the original A/C compressor (1) and place

it on a workbench (refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/COMPRESSOR-A/C -
REMOVAL).

2. Using a suitable clean measured container, position

the A/C compressor so that the refrigerant oil can
drain out of the suction port (2). Hold the A/C com-
pressor in this position until no more oil comes out
of the compressor port.

3. Reposition the A/C compressor (1) so that the pul-

ley (2) is facing downward and rotate the compres-
sor pulley clockwise ten full turns. Make sure that
each rotation of the pulley is performed within two
seconds.

24 - 160

PLUMBING

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