Before You Begin:
* Safety First: Automotive AC systems contain refrigerant under high pressure. Improper handling can cause serious injury or death. You MUST have the proper tools and training to handle refrigerant. Consider this job too dangerous to attempt without professional training and experience. At a minimum, you need AC recovery and recharge equipment.
* Repair Manual: Obtain a factory service manual or a reputable aftermarket repair manual specific to your 1995 Dodge Caravan. This will provide detailed instructions, torque specifications, and diagrams.
* Tools: You'll need a variety of tools, including wrenches, sockets, screwdrivers, a refrigerant recovery/recharge machine, a vacuum pump, possibly a compressor clutch puller, and potentially a charging hose set.
General Steps (Highly Simplified):
1. Recover Refrigerant: Use the refrigerant recovery machine to safely remove all refrigerant from the AC system. This is crucial for environmental safety and your own well-being.
2. Disconnect Components: Disconnect the AC high and low-pressure lines from the compressor. These connections will likely require special AC service tools. Note the location of the lines to ensure correct reinstallation.
3. Remove the Compressor Clutch: This may require a specialized compressor clutch puller. Be careful not to damage the compressor shaft.
4. Disconnect Electrical Connections: Disconnect the electrical connector to the compressor clutch.
5. Remove the Compressor Mounting Bolts: Locate and remove the bolts securing the compressor to the engine.
6. Remove the Compressor: Carefully remove the old compressor from the engine.
7. Install the New Compressor: Install the new compressor, ensuring it's correctly aligned and seated. Tighten the mounting bolts to the specifications in your repair manual.
8. Reconnect Components: Reconnect the electrical connector, AC lines, and the compressor clutch. Be sure to use new O-rings on the AC lines.
9. Evacuate and Recharge the System: Use the vacuum pump to evacuate the system of air and moisture. Then, charge the system with the correct amount and type of refrigerant as specified in your repair manual. This typically requires a refrigerant charging scale and gauge set.
10. Test the System: After recharging, thoroughly test the system for leaks and proper cooling performance.
Disclaimer: This is a simplified overview. Replacing an AC compressor is a complex procedure involving potentially hazardous materials and components. Attempting this repair without the proper knowledge, tools, and safety precautions could result in injury or damage to your vehicle. It's strongly recommended to have a qualified mechanic perform this repair. The steps and specific procedures may vary depending on the exact engine and AC system configuration in your 1995 Dodge Caravan. Always consult a repair manual for detailed, vehicle-specific instructions.
