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REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45SYSTEM EVACUATE . . . . . . . . . . . . . . . . . . . 35
SUCTION LINE
STANDARD PROCEDURE - REFRIGERANT
SYSTEM CHARGE. . . . . . . . . . . . . . . . . . . . . 35
. . . . . 35SPECIFICATIONS - CHARGE CAPACITY
REMOVAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
REMOVAL - 5.9L DIESEL ENGINE . . . . . . . . . 46A/C COMPRESSOR
DESCRIPTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 35
DESCRIPTION - HIGH PRESSURE RELIEFVALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION - HIGH PRESSURE RELIEFVALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DIAGNOSIS AND TESTING - A/C
COMPRESSOR NOISE
. . . . . . . . . . . . . . . . . 36
REMOVAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
REMOVAL - 5.9L DIESEL ENGINE . . . . . . . . . 37INSTALLATION
INSTALLATION INSTALLATION - 5.9L DIESEL ENGINE
. . . . . . . . . . . . . . . . . . . . . . . 38
. . . . . 39A/C CONDENSER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVALREMOVAL - 3.7, 4.7 and 5.7L ENGINES . . . . 39
REMOVAL - 5.9L DIESEL ENGINE . . . . . . . . . 40
REMOVAL - 8.0L Engine . . . . . . . . . . . . . . . . 40INSTALLATION
INSTALLATION - 3.7, 4.7 and 5.7L ENGINES . 41
INSTALLATION - 5.9L DIESEL ENGINE . . . . . 42
. . . . . . . . . . . . . 42
INSTALLATION - 8.0L EngineINSTALLATION
INSTALLATION INSTALLATION A/C EVAPORATOR
. . . . . . . . . . . . . . . . . . . . . . . 46
. . . . . . . . . . . . . . . . . . . . . . . 47DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 47
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47A/C ORIFICE TUBE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 48
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DIAGNOSIS AND TESTING - FIXED ORIFICETUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49ACCUMULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 49
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50HEATER CORE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50REFRIGERANT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
DIAGNOSIS AND TESTING- REFRIGERANTSYSTEM LEAKS
. . . . . . . . . . . . . . . . . . . . . . 51
24 - 32
PLUMBING
DR
STANDARD PROCEDURE
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE . . . . . . . . . . . . . . . . . . . 51
STANDARD PROCEDURE- REFRIGERANT
RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 52
STANDARD PROCEDURE- REFRIGERANT
SYSTEM CHARGE. . . . . . . . . . . . . . . . . . . . . 52
REFRIGERANT LINE COUPLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 52
PLUMBING DESCRIPTION - REFRIGERANT LINE
The refrigerant lines and hoses are used to carry the refrigerant between the various air conditioning system components. A barrier hose design with a nylon tube, which is sandwiched between rubber lay- ers, is used for the R-134a air conditioning system on this vehicle. This nylon tube helps to further contain the R-134a refrigerant, which has a smaller molecu- lar structure than R-12 refrigerant. The ends of the refrigerant hoses are made from lightweight alumi- num or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant plumb- ing will reduce the capacity of the entire air condi- tioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3
inches) from an exhaust manifold.OPERATION- REFRIGERANT LINES
High pressures are produced in the refrigerant sys- tem when the air conditioning compressor is operat- ing. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed.
The refrigerant lines and hoses are coupled with other components of the HVAC system with either 3
O-ring spring lock couplings or dual axes seals.The refrigerant lines and hoses cannot be repaired
and, if faulty or damaged, they must be replaced.
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 53REFRIGERANT OIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 54
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
STANDARD PROCEDURE - REFRIGERANTOIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
WARNING
SERVICE WARNINGS
WARNING: THE AIR CONDITIONING SYSTEM CON- TAINS REFRIGERANT UNDER HIGH PRESSURE. SEVERE PERSONAL INJURY MAY RESULT FROM IMPROPER SERVICE PROCEDURES. REPAIRS SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL. AVOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST. EXPOSURE MAY IRRITATE THE EYES, NOSE, AND/OR THROAT. WEAR EYE PROTECTION WHEN SERVICING THE AIR CONDITIONING REFRIGERANT SYSTEM. SERI- OUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE REFRIGERANT. IF EYE CON- TACT OCCURS, SEEK MEDICAL ATTENTION IMME- DIATELY. DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME. POISONOUS GAS IS CREATED WHEN REFRIGERANT IS BURNED. AN ELECTRONIC LEAK DETECTOR IS RECOMMENDED. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE THE WORK AREA BEFORE RESUMING SERVICE. LARGE AMOUNTS OF REFRIGERANT RELEASED IN A CLOSED WORK AREA WILL DIS- PLACE THE OXYGEN AND CAUSE SUFFOCATION. THE EVAPORATION RATE OF R-134a REFRIGER- ANT AT AVERAGE TEMPERATURE AND ALTITUDE IS EXTREMELY HIGH. AS A RESULT, ANYTHING THAT COMES IN CONTACT WITH THE REFRIGER- ANT WILL FREEZE. ALWAYS PROTECT THE SKIN OR DELICATE OBJECTS FROM DIRECT CONTACT WITH THE REFRIGERANT. THE R-134a SERVICE EQUIPMENT OR THE VEHI- CLE REFRIGERANT SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COM- PRESSED AIR. SOME MIXTURES OF AIR AND R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS, AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROP- ERTY DAMAGE.
DR PLUMBING (Continued) CAUTION
SERVICE CAUTIONS
CAUTION: Liquid refrigerant is corrosive to metal surfaces. Follow the operating instructions supplied with the service equipment being used. Never add R-12 to a refrigerant system designed to use R-134a. Damage to the system will result. R-12 refrigerant oil must not be mixed with R-134a refrigerant oil. They are not compatible. Do not use R-12 equipment or parts on the R-134a system. Damage to the system will result. Do not overcharge the refrigerant system. This will cause excessive compressor head pressure and can cause noise and system failure. Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrig- erant. Do not remove the secondary retention clip from any spring-lock coupler connection while the refrig- erant system is under pressure. Recover the refrig- erant before removing the secondary retention clip. Open the fittings with caution, even after the sys- tem has been discharged. Never open or loosen a connection before recovering the refrigerant. The refrigerant system must always be evacuated before charging. Do not open the refrigerant system or uncap a replacement component until you are ready to ser- vice the system. This will prevent contamination in the system. Before disconnecting a component, clean the out- side of the fittings thoroughly to prevent contami- nation from entering the refrigerant system. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. Before connecting an open refrigerant fitting, always install a new seal or gasket. Coat the fitting and seal with clean refrigerant oil before connect- ing. Do not remove the sealing caps from a replacement component until it is to be installed. line, avoid sharp When installing a refrigerant bends that may restrict refrigerant flow. Position the refrigerant lines away from exhaust system compo- nents or any sharp edges, which may damage the line. Tighten refrigerant fittings only to the specified torque. The aluminum fittings used in the refriger- ant system will not tolerate overtightening. fitting, use a When disconnecting a refrigerant wrench on both halves of the fitting. This will pre-
PLUMBING
24 - 33
vent twisting of the refrigerant lines or tubes. Refrigerant oil will absorb moisture from the atmo- sphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container. Keep service tools and the work area clean. Con- tamination of the refrigerant system through care- less work habits must be avoided.
CAUTION - REFRIGERANT HOSES/LINES/ TUBES PRECAUTIONS
Kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire system. High pressures are produced in the system when it is oper- ating. Extreme care must be exercised to make sure that all refrigerant system connections are pressure tight.
A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharp bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. It is a good practice to inspect all flexible refrigerant system hose lines at least once a year to make sure they are in good con- dition and properly routed.
There are two types of refrigerant fittings: † All fittings with O-rings need to be coated with refrigerant oil before installation. Use only O-rings that are the correct size and approved for use with R-134a refrigerant. Failure to do so may result in a leak.† Unified plumbing connections with gaskets can- not be serviced with O-rings. The gaskets are not reusable and new gaskets do not require lubrication before installing.
Using the proper tools when making a refrigerant plumbing connection is very important. Improper tools or improper use of the tools can damage the refrigerant fittings. Always use two wrenches when loosening or tightening tube fittings. Use one wrench to hold one side of the connection stationary, while loosening or tightening the other side of the connec- tion with a second wrench.
The refrigerant must be recovered completely from the system before opening any fitting or connection. Open the fittings with caution, even after the refrig- erant has been recovered. If any pressure is noticed as a fitting is loosened, tighten the fitting and recover the refrigerant from the system again.
Do not discharge refrigerant into the atmosphere. Use an R-134a refrigerant recovery/recycling device that meets SAE Standard J2210.
PLUMBING
24 - 34
PLUMBING (Continued)DR
The refrigerant system will remain chemically sta- ble as long as pure, moisture-free R-134a refrigerant and refrigerant oil is used. Dirt, moisture, or air can upset this chemical stability. Operational troubles or serious damage can occur if is present in the refrigerant system.
foreign material
When it is necessary to open the refrigerant sys- tem, have everything needed to service the system ready. The refrigerant system should not be left open to the atmosphere any longer than necessary. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture. All lines and components in parts stock should be capped or sealed until they are to be installed.
All tools, including the refrigerant recycling equip- ment, the manifold gauge set, and test hoses should be kept clean and dry. All tools and equipment must be designed for R-134a refrigerant.
STANDARD PROCEDURE
STANDARD PROCEDURE - REFRIGERANT SYSTEM SERVICE EQUIPMENT
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
When servicing the air conditioning system, a R-134a refrigerant recovery/recycling/charging sta- tion that meets SAE Standard J2210 must be used. Contact an automotive service equipment supplier for refrigerant equipment. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment.
recovery/recycling/charging
A manifold gauge set may be needed with some recovery/recycling/charging equipment (Fig. 1). The service hoses on the gauge set being used should have manual (turn wheel), or automatic back-flow valves at the service port connector ends. This will prevent refrigerant from being released into the atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set on an R-134a system. The refrigerants are not com- patible and system damage will result.
LOW PRESSURE GAUGE HOSE The low pressure hose (Blue with Black stripe) attaches to the suction
Fig.1MANIFOLDGAUGESET-TYPICAL
1 - HIGH PRESSURE GAUGE 2 - VALVE 3 - VACUUM/REFRIGERANT HOSE (YELLOW W/ BLACK STRIPE) 4 - HIGH PRESSURE HOSE (RED W/ BLACK STRIPE) 5 - LOW PRESSURE HOSE (BLUE W/ BLACK STRIPE) 6 - VALVE 7 - LOW PRESSURE GAUGE
service port. This port is located on the suction line between the accumulator outlet and the compressor. HIGH PRESSURE GAUGE HOSE The high pres- sure hose (Red with Black stripe) attaches to the dis- charge service port. This port is located on the liquid line between the condenser outlet and the evaporator. RECOVERY/RECYCLING/EVACUATION/CHARG- ING HOSE The center manifold hose (Yellow, or White, with Black stripe) is used to recover, evacu- ate, and charge the refrigerant system. When the low or high pressure valves on the manifold gauge set are opened, the refrigerant in the system will escape through this hose.
STANDARD PROCEDURE - REFRIGERANT RECOVERY
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to recover the refrigerant from an R-134a refrig-
DR PLUMBING (Continued)
PLUMBING
24 - 35
erant system. Refer to the operating instructions sup- plied by the equipment manufacturer for the proper care and use of this equipment.
STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE
STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be charged. If moisture and air enters the system and becomes mixed with the refrigerant, the com- pressor head pressure will rise above acceptable operating levels. This will reduce the performance of the air conditioner and damage the compressor. Evacuating the refrigerant system will remove the air and boil the moisture out of the system at near room temperature. To evacuate the refrigerant sys- tem, use the following procedure:
(1) Connect a R-134a refrigerant recovery/recy- cling/charging station that meets SAE Standard J2210 and a manifold gauge set to the refrigerant system of the vehicle.
(2) Recover the refrigerant(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE).
(3) Open the low and high side valves and start the charging station vacuum pump. When the suc- tion gauge reads 88 kPa (26 in. Hg.) vacuum or greater, close all of the valves and turn off the vac- uum pump.
(a) If the refrigerant system fails to reach the specified vacuum, the system has a leak that must be corrected. (Refer to 24 - HEATING & AIR CON- DITIONING/PLUMBING - DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM LEAKS)
(b) If the refrigerant system maintains the spec- ified vacuum for five minutes, restart the vacuum pump, open the suction and discharge valves and evacuate the system for an additional ten minutes. (4) Close all of the valves, and turn off the charg-
ing station vacuum pump.
(5) The refrigerant system is now ready to be charged with R-134a refrigerant. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM CHARGE)
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
After the refrigerant system has been tested for leaks and evacuated, a refrigerant charge can be injected into the system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - SPECIFICA- TIONS - CHARGE CAPACITY)
A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. Refer to the operating instructions sup- plied by the equipment manufacturer for proper care and use of this equipment.
The R-134a refrigerant charge capacity for this
vehicle is 0.7371 Kg (26 oz.).
NOTE: Always refer to the HVAC underhood sticker for current refrigerant charge level and refrigerant oil specifications.
SPECIFICATIONS - CHARGE CAPACITY
The R-134a refrigerant system charge capacity for
this vehicle is: 0.7371 Kg. (26 oz.).
A/C COMPRESSOR
DESCRIPTION
DESCRIPTION
The air conditioning system uses a Sanden SD-7
reciprocating swash plate-type compressor on all models. This compressor has a fixed displacement of 165 cubic centimeter and has both the suction and discharge ports located on the cylinder head. A label identifying the use of R-134a refrigerant is located on the compressor.DESCRIPTION - HIGH PRESSURE RELIEF VALVE
A high pressure relief valve is located on the com- pressor cylinder head, which is on the rear of the compressor. This mechanical valve is designed to vent refrigerant from the system to protect against damage to the compressor and other system compo-
PLUMBING
24 - 36
A/C COMPRESSOR (Continued)nents, caused by condenser air flow restriction or an overcharge of refrigerant.
OPERATION
OPERATION
The compressor is driven by the engine through an electric clutch, drive rotor and belt arrangement. The compressor is lubricated by refrigerant oil that is cir- culated throughout the refrigerant system with the refrigerant.
The compressor draws in low-pressure refrigerant vapor from the evaporator through its suction port. It then compresses the refrigerant into a high-pressure, high-temperature refrigerant vapor, which is then pumped to the condenser through the compressor dis- charge port.
The compressor cannot be repaired. If faulty or damaged, the entire compressor assembly must be replaced. The compressor clutch, pulley and clutch coil are available for service.
OPERATION - HIGH PRESSURE RELIEF VALVE The high pressure relief valve vents the system when a discharge pressure of 3445 to 4135 kPa (500
to 600 psi) or above is reached. The valve closes when a minimum discharge pressure of 2756 kPa (400 psi) is reached.The high pressure relief valve vents only enough refrigerant to reduce the system pressure, and then re-seats itself. The majority of the refrigerant is con- served in the system. If the valve vents refrigerant, it does not mean that the valve is faulty.
The high pressure relief valve is a factory-cali- brated unit. The valve cannot be adjusted or repaired, and must not be removed or otherwise dis- turbed. The valve is only serviced as a part of the compressor assembly.
DIAGNOSIS AND TESTING - A/C COMPRESSOR NOISE
When investigating an air conditioning related noise, you must first know the conditions under which the noise occurs. These conditions include: weather, vehicle speed, transmission in gear or neu- tral, engine speed, engine temperature, and any other special conditions. Noises that develop during air conditioning operation can often be misleading. For example: What sounds like a failed front bearing or connecting rod, may be caused by loose bolts, nuts, mounting brackets, or a loose compressor clutch assembly.
Drive belts are speed sensitive. At different engine speeds and depending upon belt tension, belts can develop noises that are mistaken for a compressor
DR
noise. Improper belt tension can cause a misleading noise when the compressor clutch is engaged, which may not occur when the compressor clutch is disen- gaged. Check the serpentine drive belt condition and tension as described in Cooling before beginning this procedure.
(1) Select a quiet area for testing. Duplicate the complaint conditions as much as possible. Switch the compressor on and off several times to clearly iden- tify the compressor noise. Listen to the compressor while the clutch is engaged and disengaged. Probe the compressor with an engine stethoscope or a long screwdriver with the handle held to your ear to bet- ter localize the source of the noise.
(2) Loosen all of the compressor mounting hard- ware and retighten. Tighten the compressor clutch mounting nut. Be certain that the clutch coil is mounted securely to the compressor, and that the clutch plate and rotor are properly aligned and have the correct air gap. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/A/C COMPRESSOR CLUTCH - INSTALLATION)
(3) To duplicate a high-ambient temperature condi- tion (high head pressure), restrict the air flow through the condenser. Install a manifold gauge set to be certain that the discharge pressure does not exceed 2760 kPa (400 psi).
(4) Check the refrigerant system plumbing for incorrect routing, rubbing or interference, which can cause unusual noises. Also check the refrigerant lines for kinks or sharp bends that will restrict refrigerant flow, which can cause noises. (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING - CAU- TION)
(5) If the noise is from opening and closing of the high pressure relief valve, evacuate and recharge the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO- CEDURE - REFRIGERANT SYSTEM EVACUATE) (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - STANDARD PROCEDURE - REFRIG- ERANT SYSTEM CHARGE) If the high pressure relief valve still does not seat properly, replace the compressor.
(6) If the noise is from liquid slugging on the suc- tion line. Check the refrigerant oil level and the refrigerant system charge. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGER- ANT OIL - STANDARD PROCEDURE) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - SPECIFICATIONS - CHARGE CAPACITY) If either is out of specification range reclaim, evacuate and recharge the refrigerent system(Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING/REFRIG- ERANT - STANDARD PROCEDURE), (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/RE-
DR A/C COMPRESSOR (Continued)
PLUMBING
24 - 37
FRIGERANT - STANDARD PROCEDURE) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/REFRIGERANT - STANDARD PROCE- DURE). If the liquid slugging condition continues replace the accumulator(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/ACCUMULATOR - REMOVAL). If after replaceing the accumulator the slugging condition still exists then replace the com- pressor.(Refer to 24 - HEATING & AIR CONDITION- ING/PLUMBING/A/C COMPRESSOR - REMOVAL)
(7) If the noise continues, replace the compressor
and repeat Step 1.
REMOVAL
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
The compressor may be removed and repositioned without disconnecting the refrigerant lines or dis- charging the refrigerant system. Discharging is not necessary if servicing the compressor clutch or clutch coil, the engine, the cylinder head, or the generator. (1) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT RECOVERY)
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the serpentine drive belt(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(4) Unplug the compressor clutch coil wire harness
connector.
(5) Remove the suction and discharge refrigerant line manifold from the compressor. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/ SUCTION LINE - REMOVAL) (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING/A/C DISCHARGE LINE - REMOVAL) Install plugs in, or tape over all of the opened refrigerant fittings.
(6) Remove the bolts that secure the compressor to
the mounting bracket (Fig. 2).
(7) Remove the compressor from the mounting
bracket.
REMOVAL - 5.9L DIESEL ENGINE
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE
Fig.2A/CCOMPRESSOR-3.7LENGINE-(typical
4.7,5.7&8.0L)
1 - COMPRESSOR BOLT #1
2 - COMPRESSOR BOLT #2
3 - COMPRESSOR BOLT #3
4 - A/C COMPRESSOR 5 - A/C COMPRESSOR CLUTCH AND PULLEY 6 - COMPRESSOR MOUNTPERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
The compressor may be removed and repositioned without disconnecting the refrigerant lines or dis- charging the refrigerant system. Discharging is not necessary if servicing the compressor clutch or clutch coil, the engine, the cylinder head, or the generator. (1) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT RECOVERY)
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the serpentine drive belt(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(4) Unplug the compressor clutch coil wire harness
connector.
(5) Remove the bolt that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings.
(6) Remove the four bolts that secure the compres-
sor to the mounting bracket (Fig. 3).
(7) Remove the a/c compressor from the mounting
bracket.
PLUMBING
24 - 38
A/C COMPRESSOR (Continued)DR
AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - DESCRIPTION)
(1) Install the compressor to the mounting bracket. (2) On the 3.7L, 4.7L, 5.7L and 8.0L gasoline engines install and tighten the bolts in the following sequence (Fig. 4): † The number one bolt (rear) is hand tightened † The number three bolt is then hand tightened † The number two bolt is also hand tightened and
first then tightened to 55 N·m (41 ft. lbs.)
and torqued to 40 N·m ( 30 ft. lbs.)
torqued to 55 N·m ( 41 ft. lbs.)
Fig.3COMPRESSORREMOVE/INSTALL-DIESEL
ENGINE
1 - ENGINE 2 - BRACKET 3 - A/C COMPRESSOR 4 - BOLTS
INSTALLATION
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION - REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS)
The compressor may be removed and repositioned without disconnecting the refrigerant lines or dis- charging the refrigerant system. Discharging is not necessary if servicing the compressor clutch or clutch coil, the engine, the cylinder head, or the generator.
If a replacement compressor
NOTE: is being installed, be certain to check the refrigerant oil level. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/REFRIGERANT OIL - STANDARD PRO- CEDURE - REFRIGERANT OIL LEVEL) Use only refrigerant oil of the type recommended for the compressor in the vehicle. (Refer to 24 - HEATING &
Fig.4A/CCOMPRESSOR-3.7LENGINE-(typical
4.7,5.7&8.0L)
1 - COMPRESSOR BOLT #1
2 - COMPRESSOR BOLT #2
3 - COMPRESSOR BOLT #3
4 - A/C COMPRESSOR 5 - A/C COMPRESSOR CLUTCH AND PULLEY 6 - COMPRESSOR MOUNT(3) Remove the tape or plugs from all of the opened refrigerant line fittings. Install the suction and discharge line manifold to the compressor. Tighten the fastener to 28 N·m (250 in. lbs.).(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/ SUCTION LINE - INSTALLATION) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C DISCHARGE LINE - INSTALLATION)
(4) Install the serpentine drive belt(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(5) Plug in the compressor clutch coil wire harness
connector.
(6) Connect the battery negative cable.
DR A/C COMPRESSOR (Continued)
(7) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM EVACUATE)
(8) Charge the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM CHARGE)
INSTALLATION - 5.9L DIESEL ENGINE
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION - REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS)
If a replacement compressor
NOTE: is being installed, be certain to check the refrigerant oil level. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/REFRIGERANT OIL - STANDARD PRO- CEDURE) Use only refrigerant oil of the type recommended for the compressor in the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/REFRIGERANT OIL - DESCRIPTION)
(1) Install the compressor to the mounting bracket. Tighten the four mounting bolts to 24 N·m (210 in. lbs.).
(2) Remove the tape or plugs from all of the opened refrigerant line fittings. Install the suction and discharge line manifold to the compressor. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMB- ING/A/C SUCTION AND DISCHARGE LINE - INSTALLATION)
(3) Install the serpentine drive belt(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(4) Plug in the compressor clutch coil wire harness
connector.
(5) Connect the battery negative cable. (6) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM CHARGE)
PLUMBING
24 - 39
A/C CONDENSER DESCRIPTION
The condenser is located in the air flow next to the engine cooling radiator. The condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the compressor to give up its heat to the air passing over the condenser fins.
OPERATION
When the refrigerant gas gives up its heat, it con- denses. When the refrigerant leaves the condenser, it has become a high-pressure liquid refrigerant. The volume of air flowing over the condenser fins is crit- ical to the proper cooling performance of the air con- ditioning system. Therefore, it is important that there are no objects placed in front of the radiator grille openings in the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radia- tor or condenser service.
The condenser cannot be repaired and, if faulty or
damaged, it must be replaced.
REMOVAL
REMOVAL - 3.7, 4.7 and 5.7L ENGINES
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT RECOVERY)
(3) Disconnect the discharge line refrigerant line fitting at the condenser inlet. (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING - STAN- DARD PROCEDURE - A/C LINE COUPLERS) Install plugs in, or tape over all of the opened refrig- erant line fittings.
(4) Disconnect the liquid line refrigerant line fit- ting at the condenser outlet. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - A/C LINE COUPLERS) Install plugs in, or tape over all of the opened refrigerant line fit- tings.
PLUMBING
24 - 40
A/C CONDENSER (Continued)DR
(5) Disconnect the condenser cooling fan electric
connector.
PLER) Install plugs in, or tape over all of the opened refrigerant line fittings.
(6) Remove the two nuts that secure the condenser
(5) On diesel engine models:
studs to the upper cross brace. (Fig. 5).
(a) Remove the two screws that secure the brackets on the passenger side end of the con- denser to the charge air cooler (Fig. 6).
(b) Remove the two nuts that secure the driver side end of the condenser to the studs on the charge air cooler.
(c) Remove the condenser from the vehicle.
Fig.5CondenserModule
1 - Condensor Module Mounting Screw 2 - Front Cross Member 3 - Lower Module Mounting Flang 4 - Fan Assembly Mounting Screw 5 - Fan Assembly Mounting Screw 6 - Condensor Mounting Tabs 7 - Condensor Fan Assembly 8 - Fan Power Connector 9 - Condensor Module Mounting Screw
(7) Remove the condenser and fan assembly from
the vehicle.
REMOVAL - 5.9L DIESEL ENGINE
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT RECOVERY)
(3) Remove the nut that secures the block fitting to the stud on the condenser inlet, and disconnect the discharge line from the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings.
(4) Disconnect
the refrigerant
line fitting that secures the liquid line to the condenser outlet. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMB- ING - STANDARD PROCEDURE - A/C LINE COU-
Fig.6CONDENSER-DIESELENGINE
1 - Discharge line to condenser 2 - Condensor mounting bolt 3 - Liquid Line 4 - Condenser mounting bolt 5 - A/C condenser 6 - Condenser mounting bolt 7 - Condenser mounting bolt
REMOVAL - 8.0L Engine
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN TEH FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) AND (Refer to 24 - HEATING & AIR CON- DITIONING/PLUMBING - CAUTION).
(1) Remove battery negative cable. (2) Recover refrigerant from a/c system(Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE).DR A/C CONDENSER (Continued)
NOTE: Removal of the front bumper on the V-10 is required, failure to do so could result in damage to the condenser assembly and the bumper.
PLUMBING
24 - 41
(3) Remove the front bumper assembly from the - FRAME & BUMPERS/
vehicle(Refer BUMPERS/FRONT BUMPER - REMOVAL).
13
to
(4) Remove hood latch bolts and set hood latch assembly aside(Refer to 23 - BODY/HOOD/LATCH - REMOVAL).
(5) Remove a/c lines from condenser(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C DISCHARGE LINE - REMOVAL) and (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/ SUCTION LINE - REMOVAL). Install plugs or tape over all open connections (Fig. 7).
Fig.8A/CCONDENSER
1 -A/C shroud mounting bolt 2 - Hood latch bolt 3 - Hood latch assembly 4 - Hood latch bolt 5 - A/C shroud mounting bolt 6 - A/C discharge line 7 - A/C liquid line 8 - Condenser to shroud mounting bolts (5) 9 - A/C condenser 10 - Condenser to shroud mounting bolts (5)
INSTALLATION
INSTALLATION - 3.7, 4.7 and 5.7L ENGINES
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION - REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS)
Fig.7CONDENSERLINES
1 - Discharge line to condenser 2 - Mounting nut 3 - Mounting nut 4 - Liquid line 5 - A/C condenser shroud 6 - A/C condenser
(6) Remove two bolts from top of condenser shroud
assembly (Fig. 8).
(7) Lift condenser and shift assembly to passenger
side of vehicle and remove from vehicle.
(8) With condenser and shroud on a clean flat work area remove condenser retainer screws and sep- arate condenser from shroud.
(1) Install the condenser lower dowel pins to the
bottom of the support rail.
(2) Position the condenser until both of the con- denser studs are installed through the holes in the upper support rail. Tighten the mounting nuts to 5.3
N·m (47 in. lbs.).(3) Remove the tape or plugs from the refrigerant line fittings on the condenser outlet and the liquid line. Install the liquid line or the liquid line jumper to the condenser outlet. (Refer to 24 - HEATING &
PLUMBING
24 - 42
A/C CONDENSER (Continued)DR
AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - A/C LINE COUPLERS)
(4) Remove the tape or plugs from the refrigerant line fittings on the condenser inlet and the discharge line. Connect the discharge line to the condenser inlet. (Refer to 24 - HEATING & AIR CONDITION- ING/PLUMBING - STANDARD PROCEDURE - A/C LINE COUPLERS)
(5) Connect the battery negative cable. (6) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM CHARGE)
NOTE: If the condenser is replaced, add 30 millili- ters (1 fluid ounce) of refrigerant oil to the refriger- ant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/REFRIGERANT OIL - DESCRIPTION)
INSTALLATION - 5.9L DIESEL ENGINE
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION - REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS)
(1) On diesel engine models:
(a) Install the driver side condenser mounting brackets over the two studs on the charge air cooler.
(b) Install the two screws that secure the brack- ets on the passenger side end of the condenser to the charge air cooler. Tighten the mounting screws to 10.5 N·m (95 in. lbs.).
(c) Install the two nuts that secure the driver side end of the condenser to the studs on the charge air cooler. Tighten the mounting nuts to 10.5 N·m (95 in. lbs.). (2) Remove the plugs or tape from the refrigerant line fittings on the liquid line and the condenser out- let. Connect the liquid line to the condenser outlet. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - STANDARD PROCEDURE - A/C LINE COUPLERS)
(3) Install a new gasket and the discharge line block fitting over the stud on the condenser inlet. Tighten the mounting nut to 20 N·m (180 in. lbs.).
(4) Check that all of the condenser and radiator
air seals are in their proper locations.
(5) Connect the battery negative cable. (6) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM CHARGE)
NOTE: If the condenser is replaced, add 30 millili- ters (1 fluid ounce) of refrigerant oil to the refriger- ant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/REFRIGERANT OIL - DESCRIPTION)
INSTALLATION - 8.0L Engine
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) AND (Refer to 24 - HEATING & AIR CON- DITIONING/PLUMBING - CAUTION).
(1) If the condenser was removed from the shroud,
install it and tighten the mounting screws.
(2) Install the condenser and shroud in the vehicle. Make sure the lower mounting flanges are positioned correctly before installing the two mounting screws to the radiator brace. Tighten the screws to spec.
(3) Remove and plugs or tape installed over the
condenser connections and the a/c lines.
(4) Install the lines to the condenser(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C DISCHARGE LINE - INSTALLATION) and (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/ SUCTION LINE - INSTALLATION).
(5) Install the hood latch assembly(Refer to 23 -
BODY/HOOD/LATCH - INSTALLATION).
(6) Install the front bumper assembly(Refer to 13 - FRAME & BUMPERS/BUMPERS/FRONT BUMPER - INSTALLATION).
(7) Evacuate the a/c system(Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING - STAN- DARD PROCEDURE).
DR A/C CONDENSER (Continued)
NOTE: If the condenser is replaced, add 30 millili- ters (1 fluid ounce) of refrigerant oil to the refriger- ant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle(Re- fer to 24 - HEATING & AIR CONDITIONING/PLUMB- ING/REFRIGERANT OIL - DESCRIPTION).
(8) Charge the a/c system(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE).
(9) Install the battery negative cable.
A/C CONDENSER FAN REMOVAL - CONDENSER FAN (GAS ENGINE ONLY - 3.7, 4.7 & 5.7L)
(1) Remove and isolate negative battery cable. (2) Remove condenser assembly(Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C CONDENSER - REMOVAL).
(3) Place condenser assembly on a flat work area and remove screws holding fan assembly to con- denser.
(4) Separate fan assembly from condenser noting
location of all seals for reinstallation.
INSTALLATION - CONDENSER FAN (GAS ENGINE ONLY - 3.7, 4.7 & 5.7L)
(1) Position fan assembly on to the condenser. (2) Check all
fan shroud seals and replace as required then install retainer screws to hold fan assembly to condenser.
(3) Install condenser and fan assembly to vehi- cle(Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/A/C CONDENSER - INSTALLATION).
(4) Install battery negative cable.
A/C DISCHARGE LINE
REMOVAL
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDI-
PLUMBING
24 - 43
TIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT RECOVERY)
(3) Unplug the wire harness connector from the
high pressure transducer.
(4) Disconnect the discharge line refrigerant line fitting from the condenser inlet tube (Fig. 9). (Refer to 24 - HEATING & AIR CONDITIONING/PLUMB- ING - STANDARD PROCEDURE - A/C LINE COU- PLERS) Install plugs in, or tape over all of the opened refrigerant line fittings.
Fig.9A/CDischargeLine
1 - Discharge Line Retainer Nut 2 - Front Upper Cross Brace 3 - Condensor Module Port 4 - Suction and Discharge Line Retainer Screw 5 - Suction Line 6 - A/C Compressor 7 - High Pressure Transducer Connector 8 - Discharge Line
(5) Disconnect the connection that secures the suc- tion line fitting to the accumulator outlet. Install plugs in, or tape over all of the opened refrigerant line fittings.
(6) Remove the screw that secures the suction and discharge line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings.
(7) Remove the suction and discharge line assem-
bly from the vehicle.
REMOVAL - 5.9L DIESEL ENGINE
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the battery negative
cable.
PLUMBING
24 - 44
A/C DISCHARGE LINE (Continued)DR
(2) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT RECOVERY)
(3) Unplug the wire harness connector from the a/c
high pressure switch.
(4) Disconnect the suction line refrigerant line cou- pler at the accumulator. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - A/C LINE COUPLER) Install plugs in, or tape over all of the opened refrigerant line fit- tings.
(5) Remove the nut that secures the block fitting to the stud on the condenser inlet and disconnect the discharge line from the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings.
(6) Remove the bolt that secures the refrigerant line manifold to the compressor (Fig. 10). Install plugs in, or tape over all of the opened refrigerant line fittings.
Fig.10SUCTIONANDDISCHARGELINEREMOVE/
INSTALL-DIESELENGINE
1 - DISCHARGE LINE (TO CONDENSER) 2 - COMPRESSOR 3 - BOLT 4 - MANIFOLD 5 - SUCTION LINE (FROM ACCUMULATOR) 6 - A/C HIGH PRESSURE SWITCH
(7) Remove the suction and discharge line assem-
bly from the vehicle.
INSTALLATION
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION - REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS)
(1) Remove the tape or plugs from the suction and discharge line manifold and the compressor. Install the suction and discharge line manifold to the com- pressor. Tighten the fastener to 28 N·m (250 in. lbs.). (2) Remove the tape or plugs from the suction line and the accumulator outlet fittings. Install the suc- tion line to the accumulator outlet and install fas- tener.
(3) Remove the tape or plugs from the refrigerant line fittings on the discharge line and the condenser inlet tube. Connect the discharge line refrigerant line coupler to the condenser inlet tube. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - A/C LINE COUPLERS) (4) Plug in the wire harness connector to the high
pressure transducer switch.
(5) Connect the battery negative cable. (6) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM CHARGE)
INSTALLATION - 5.9L DIESEL ENGINE
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION - REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS)
(1) Remove the tape or plugs from all of the refrig- erant line fittings. Connect the suction line refriger- ant line coupler to the accumulator. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - A/C LINE COUPLERS) (2) Install a new gasket and the discharge line block fitting over the stud on the condenser inlet. Tighten the mounting nut to 20 N·m (180 in. lbs.).
(3) Install the refrigerant line manifold to the com- pressor. Tighten the mounting bolt to 22 N·m (200 in. lbs.).
(4) Plug in the wire harness connector to the a/c
high pressure switch.
(5) Connect the battery negative cable. (6) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING -
DR A/C DISCHARGE LINE (Continued)
STANDARD PROCEDURE - REFRIGERANT SYS- TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM CHARGE)
LIQUID LINE REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the battery negative
cable.
NOTE: Removal of the second battery and battery tray is required on the diesel equipped vehicles.
(2) Remove rightside battery(Refer to 8 - ELEC- TRICAL/BATTERY SYSTEM/BATTERY - REMOV- AL).
(3) Remove rightside battery tray(Refer to 8 - ELECTRICAL/BATTERY SYSTEM/TRAY - REMOV- AL).
(4) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT RECOVERY)
(5) Disconnect the liquid line refrigerant line cou- plers at the condenser outlet the mid point connec- tion and the evaporator to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - A/C LINE COUPLERS) Install plugs in, or tape over all of the opened refrig- erant line fittings.
(Refer
inlet.
(6) Disengage any clips that secure the liquid line
to the inner fender shield or cross brace. (Fig. 11).
(7) Remove the both sections of the liquid line
from the vehicle.
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING -
PLUMBING
24 - 45
Fig.11A/CLiquidLine-GasEngineshown
1 - A/C Line Retainer Clip 2 - A/C Line Retention Clip 3 - A/C Line Retainer Clip 4 - Liquid Line to Evaporator 5 - A/C Line Retention Clip 6 - Evaporator Ports 7 - A/C Condensor Modular 8 - A/C Jumper Line Retainer Nut 9 - A/C Line Retainer Clip 10 - A/C Liquid Jumper Line
CAUTION - REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS)
(1) Install both sections of the liquid line into any clips on the inner fender shield and the dash panel. (2) Remove the tape or plugs from the refrigerant line fittings on the liquid line, the condenser outlet, and the evaporator inlet. Connect the liquid line pieces together and to the condenser and the evapo- rator. (Refer to 24 - HEATING & AIR CONDITION- ING/PLUMBING - STANDARD PROCEDURE - A/C LINE COUPLERS)
NOTE: Installation of the second battery and battery tray is required on the diesel equipped vehicles.
(3) Install the rightside battery tray(Refer to 8 - ELECTRICAL/BATTERY SYSTEM/TRAY - INSTAL- LATION).
(4) Install the rightside battery(Refer to 8 - ELEC- TRICAL/BATTERY SYSTEM/BATTERY - INSTAL- LATION).
(5) Connect the battery positive cables. (6) Connect the battery negative cables. (7) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING -
PLUMBING
24 - 46
LIQUID LINE (Continued)STANDARD PROCEDURE - REFRIGERANT SYS- TEM EVACUATE)
(8) Charge the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM CHARGE)
SUCTION LINE
REMOVAL
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
DR
TIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT RECOVERY)
(3) Unplug the wire harness connector from the a/c
high pressure switch.
(4) Disconnect the suction line refrigerant line cou- pler at the accumulator. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - A/C LINE COUPLER) Install plugs in, or tape over all of the opened refrigerant line fit- tings.
(5) Remove the nut that secures the block fitting to the stud on the condenser inlet and disconnect the discharge line from the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings.
(6) Remove the bolt that secures the refrigerant line manifold to the compressor (Fig. 12). Install plugs in, or tape over all of the opened refrigerant line fittings.
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT RECOVERY)
(3) Unplug the wire harness connector from the a/c
high pressure transducer.
(4) Disconnect the suction line refrigerant line cou- pler at the accumulator. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - A/C LINE COUPLER) Install plugs in, or tape over all of the opened refrigerant line fit- tings.
(5) Remove the nut that secures the condenser inlet and disconnect the discharge line from the con- denser. Install plugs in, or tape over all of the opened refrigerant line fittings.
(6) Remove the suction and discharge line assem-
bly from the vehicle.
REMOVAL - 5.9L DIESEL ENGINE
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDI-
Fig.12SUCTIONANDDISCHARGELINEREMOVE/
INSTALL-DIESELENGINE
1 - DISCHARGE LINE (TO CONDENSER) 2 - COMPRESSOR 3 - BOLT 4 - MANIFOLD 5 - SUCTION LINE (FROM ACCUMULATOR) 6 - A/C HIGH PRESSURE SWITCH
(7) Remove the suction and discharge line assem-
bly from the vehicle.
INSTALLATION
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION - REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS)
DR SUCTION LINE (Continued)
(1) Remove the tape or plugs from all of the refrig- erant line fittings. Connect the suction refrigerant line coupler to the accumulator. (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING - STAN- DARD PROCEDURE - A/C LINE COUPLERS)
(2) Install a new gasket and the discharge line block fitting over the stud on the condenser inlet. Tighten the mounting nut to 20 N·m (180 in. lbs.).
(3) Install the refrigerant line manifold to the com- pressor. Tighten the mounting bolt to 22 N·m (200 in. lbs.).
(4) Plug in the wire harness connector to the A/C
high pressure transducer.
(5) Connect the battery negative cable. (6) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM CHARGE)
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION - REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS)
(1) Remove the tape or plugs from all of the refrig- erant line fittings. Connect the suction line refriger- ant line coupler to the accumulator. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - A/C LINE COUPLERS) (2) Install a new gasket and the discharge line block fitting over the stud on the condenser inlet. Tighten the mounting nut to 20 N·m (180 in. lbs.).
(3) Install the refrigerant line manifold to the com- pressor. Tighten the mounting bolt to 22 N·m (200 in. lbs.).
(4) Plug in the wire harness connector to the a/c
high pressure switch.
(5) Connect the battery negative cable. (6) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM CHARGE)
PLUMBING
24 - 47
A/C EVAPORATOR DESCRIPTION
The A/C evaporator is located in the HVAC hous- ing, under the instrument panel. The evaporator coil is positioned in the HVAC housing so that all air that enters the housing must pass over the fins of the evaporator before it is distributed through the sys- tem ducts and outlets. However, air passing over the evaporator coil fins will only be conditioned when the compressor is engaged and circulating refrigerant through the evaporator coil tubes.
OPERATION
Refrigerant enters the evaporator from the fixed orifice tube as a low-temperature, low-pressure liq- uid. As air flows over the fins of the evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vapor- ize. The refrigerant becomes a low-pressure gas when it leaves the evaporator.
The evaporator coil cannot be repaired and,
if
faulty or damaged, it must be replaced.
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
(1) Remove the HVAC housing from the vehicle, and disassemble the housing halves. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/ HVAC HOUSING - REMOVAL) (Refer to 24 - HEAT- ING & AIR CONDITIONING/DISTRIBUTION/HVAC HOUSING - DISASSEMBLY)
(2) Lift the A/C evaporator out of the HVAC hous-
ing (Fig. 13).
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION - REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS)
PLUMBING
24 - 48
A/C EVAPORATOR (Continued)DR
mesh diffuser screen. The O-rings on the plastic body of the fixed orifice tube seal the tube to the inside of the liquid line and prevents the refrigerant from bypassing the fixed metering orifice.
Fig.13DualZoneHVACHousing-(typicalsingle
zone)
1 - Passenger Side Blend Door Lever (if equipped) 2 - Passenger Side Blend Door (if equipped) 3 - Fin Sensor Wire 4 - Lower Blower Motor Mounting Housing 5 - HVAC Evaporator 6 - Fin Sensor 7 - Driver Side Blend Door 8 - Driver Side Blend Door Lever
(1) Insert the evaporator coil into the bottom of the HVAC housing. Make sure that the evaporator drain is clean and unrestricted and evaporator deflector shield is also installed.
(2) Reassemble and reinstall the HVAC housing in the vehicle. (Refer to 24 - HEATING & AIR CONDI- TIONING/DISTRIBUTION/HVAC ASSEMBLY) (Refer to 24 - HEATING & AIR CON- DITIONING/DISTRIBUTION/HVAC HOUSING - INSTALLATION)
HOUSING
NOTE: If the evaporator is replaced, add 60 millili- ters (2 fluid ounces) of refrigerant oil to the refrig- erant system.
A/C ORIFICE TUBE DESCRIPTION
The fixed orifice tube is installed in the liquid line between the outlet of the condenser and the inlet of the evaporator. The fixed orifice tube is only serviced as an integral part of the liquid line.
OPERATION
The inlet end of the fixed orifice tube has a nylon mesh filter screen, which filters the refrigerant and helps to reduce the potential for blockage of the metering orifice by refrigerant system contaminants (Fig. 14). The outlet end of the tube has a nylon
Fig.14FIXEDORIFICETUBE-TYPICAL
1 - DIFFUSER SCREEN 2 - “O” RINGS 3 - INLET FILTER SCREEN 4 - ORIFICE
The fixed orifice tube is used to meter the flow of liquid refrigerant into the evaporator coil. The high- pressure condenser expands into a low-pressure liquid as it passes through the metering orifice and diffuser screen of the fixed orifice tube.
liquid refrigerant
from the
The fixed orifice tube cannot be repaired and, if faulty or plugged, the liquid line assembly must be replaced.
DIAGNOSIS AND TESTING - FIXED ORIFICE TUBE
The fixed orifice tube can be checked for proper operation using the following procedure. However, the fixed orifice tube is only serviced as a part of the liquid line unit. If the results of this test indicate that the fixed orifice tube is obstructed or missing, the entire liquid line unit must be replaced.
WARNING: THE LIQUID LINE BETWEEN THE CON- DENSER OUTLET AND THE FIXED ORIFICE TUBE CAN BECOME HOT ENOUGH TO BURN THE SKIN. USE EXTREME CAUTION WHEN PERFORMING THE FOLLOWING TEST.
(1) Confirm that the refrigerant system is properly charged. (Refer to 24 - HEATING & AIR CONDI- TIONING - DIAGNOSIS AND TESTING - A/C PER- FORMANCE)
(2) Start the engine. Turn on the air conditioning system and confirm that the compressor clutch is engaged.
(3) Allow the air conditioning system to operate for
five minutes.
(4) Lightly and cautiously touch the liquid line near the condenser outlet at the front of the engine
DR A/C ORIFICE TUBE (Continued)
PLUMBING
24 - 49
compartment. The liquid line should be hot to the touch.
(5) Touch the liquid line near the evaporator inlet at the rear of the engine compartment. The liquid line should be cold to the touch.
(6) If there is a distinct temperature differential between the two ends of the liquid line, the orifice tube is in good condition. If there is little or no detectable temperature differential between the two ends of the liquid line, the orifice tube is obstructed or missing and the liquid line must be replaced.
REMOVAL
The fixed orifice tube is located in the liquid line, between the condenser and the evaporator coil. The orifice has filter screens on the inlet and outlet ends of the tube body. If the fixed orifice tube is faulty or plugged, the liquid line assembly must be replace- d(Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/LIQUID LINE - REMOVAL).
INSTALLATION
The fixed orifice tube is located in the liquid line, between the condenser and the evaporator coil. The orifice has filter screens on the inlet and outlet ends of the tube body. If the fixed orifice tube is faulty or plugged, the liquid line assembly must be replace- d(Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/LIQUID LINE - INSTALLATION).
ACCUMULATOR DESCRIPTION
The accumulator is mounted in the engine com- partment between the A/C evaporator outlet tube and the compressor inlet.
OPERATION
Refrigerant enters the accumulator canister as a low pressure vapor through the inlet tube. Any liq- uid, oil-laden refrigerant falls to the bottom of the canister, which acts as a separator. A desiccant bag is mounted inside the accumulator canister to absorb any moisture which may have entered and become trapped within the refrigerant system.
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT RECOVERY)
Fig.15A/CAccumulator
1 - Inner Fender 2 - Line from Accumulator to Evaporator 3 - A/C Line Rentention Clip 4 - Evaporator Ports 5 - Accumulator Mounting Screws 6 - Accumulator 7 - Suction Line 8 - A/C Charging Port 9 - A/C Line Rentention Clip
(3) Loosen the fasteners that secure the accumula- tor and support bracket to the dash panel (Fig. 15). (4) Disconnect the suction line refrigerant line fit- ting from the accumulator outlet. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - A/C LINE COUPLERS) Install plugs in, or tape over all of the opened refrig- erant line fittings.
(5) Disconnect the accumulator inlet refrigerant line fitting from the evaporator outlet. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE) Install plugs in, or tape over all of the opened refrigerant line fittings.
(6) Remove the accumulator assembly from the
engine compartment.
PLUMBING
24 - 50
ACCUMULATOR (Continued) INSTALLATIONWARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION - REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS)
(1) Install the accumulator to the bulkhead but do
not tighten yet.
(2) Remove the tape or plugs from the refrigerant line fittings on the accumulator inlet and the evapo- rator outlet. Connect the accumulator inlet refriger- ant line coupler to the evaporator outlet. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - A/C LINE COUPLERS) (3) Remove the tape or plugs from the refrigerant line fittings on the suction line and the accumulator outlet. Connect the suction line refrigerant line cou- pler to the accumulator outlet. (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - A/C LINE COUPLERS) (4) Tighten the accumulator fasteners to 4.5 N·m(40 in. lbs.).
(5) Connect the battery negative cable. (6) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM CHARGE)
DR
through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend door allows control of the heater output air temperature by controlling how much of the air flowing through the HVAC housing is directed through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing.
The heater core cannot be repaired and, if faulty or
damaged, it must be replaced.
REMOVAL
NOTE: Disassembly of the HVAC housing is not required to remove heater core.
(1) Remove the HVAC housing from the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/ DISTRIBUTION/HVAC HOUSING - REMOVAL)
(2) Remove the screws and retainers that secure
the heater core to the HVAC housing.
(3) Lift the heater core out of the heater-A/C hous-
(4) Inspect all seals and repair or replace as
ing.
required.
INSTALLATION
(1) Place the heater core into the HVAC housing. (2) Snap the retainers for the heater core to the housing. Install and tighten the screws that secure the heater core to the HVAC housing (if equipped). Tighten the screws to 2.2 N·m (20 in. lbs.).
(3) Reinstall the HVAC housing in the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/ DISTRIBUTION/HVAC HOUSING - INSTALLA- TION)
NOTE: If the accumulator is replaced, add 60 milli- liters (2 fluid ounces) of refrigerant oil to the refrig- erant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle.
REFRIGERANT DESCRIPTION
HEATER CORE DESCRIPTION
The heater core is located in the HVAC housing, under the instrument panel. It is a heat exchanger made of rows of tubes and fins.
The heater core is not repairable and if damaged it
must be replaced.
OPERATION
Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows
The refrigerant used in this air conditioning sys- tem is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flam- mable, clear, and colorless liquefied gas.
Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming.
OPERATION
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even aDR REFRIGERANT (Continued)
small amount of R-12 added to an R-134a refrigerant system will cause compressor failure, refrigerant oil sludge or poor air conditioning system performance. In addition, the PolyAlkylene Glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refriger- ant oils used in an R-12 refrigerant system.
R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehi- cle and on the compressor identifying to service tech- nicians that the air conditioning system is equipped with R-134a.
DIAGNOSIS AND TESTING- REFRIGERANT SYSTEM LEAKS
WARNING: (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - WARNING) and (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAU- TION).
If the air conditioning system does not cool prop- erly, the A/C system performance should be tested.
