engine oil DODGE RAM 1500 1998 2.G Workshop Manual

(4) Align the condenser lower mounting tabs to the
mounting flanges.
(5) Install the two bolts that secure the condenser/
cooling fan assembly to the upper front crossmember.
Tighten the bolts to 10.5 N´m (95 in. lbs.).
(6) Connect the wire harness connector to the con-
denser cooling fan motor.
(7) Remove the tape or plugs from the liquid line
fitting and condenser outlet port.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
Use only the specified O-ring as it is made of a spe-
cial material for the R-134a system. Use only refrig-
erant oil of the type recommended for the A/C
compressor in the vehicle.
(9) Connect the liquid line to the condenser outlet
port.
(10) Install and tighten the nut that secures the
liquid line fitting to the condenser. Tighten the nut to
20 N´m (180 in. lbs.).
(11) Install the plastic cover onto the condenser
outlet stud.
(12) Remove the tape or plugs from the discharge
line fitting and condenser inlet port.(13) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting. Use only the specified O-ring as it is made of a
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
(14) Connect the discharge line to the condenser
inlet port.
(15) Install and tighten the nut that secures the
discharge line fitting to the condenser. Tighten the
nut to 20 N´m (180 in. lbs.).
(16) Reconnect the battery negative cable.
(17) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(18) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
INSTALLATION - 5.9L DIESEL ENGINE
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.
(1) Position the condenser into the engine compart-
ment.
(2) Install the four bolts that secure the condenser
to the charge air cooler. Tighten the bolts to 10.5 N´m
(95 in. lbs.).
(3) Remove the tape or plugs from the liquid line
fitting and condenser outlet port.
(4) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
Use only the specified O-ring as it is made of a spe-
cial material for the R-134a system. Use only refrig-
erant oil of the type recommended for the A/C
compressor in the vehicle.
(5) Connect the liquid line to the condenser outlet
port.
(6) Install and tighten the nut that secures the liq-
uid line fitting to the condenser. Tighten the nut to
20 N´m (180 in. lbs.).
(7) Install the plastic cover onto the condenser out-
let stud.
(8) Remove the tape or plugs from the discharge
line fitting and condenser inlet port.
(9) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting. Use only the specified O-ring as it is made of a
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
Fig. 12 Condenser - 5.9L Diesel Engine
1 - DISCHARGE LINE
2 - MOUNTING BOLT
3 - LIQUID LINE
4 - MOUNTING BOLT
5 - A/C CONDENSER
6 - MOUNTING BOLT
7 - MOUNTING BOLT
24 - 54 PLUMBINGDR
A/C CONDENSER (Continued)

(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
Use only the specified O-ring as it is made of a spe-
cial material for the R-134a system. Use only refrig-
erant oil of the type recommended for the A/C
compressor in the vehicle.
(9) Connect the liquid line to the condenser outlet
port.
(10) Install and tighten the nut that secures the
liquid line fitting to the condenser. Tighten the nut to
20 N´m (180 in. lbs.).
(11) Install the plastic cover onto the condenser
outlet stud.
(12) Remove the tape or plugs from the suction
line fitting and condenser inlet port.
(13) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the suction line fit-
ting. Use only the specified O-ring as it is made of a
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
(14) Connect the suction line to the condenser inlet
port.
(15) Install and tighten the nut that secures the
suction line fitting to the condenser. Tighten the nut
to 20 N´m (180 in. lbs.).
(16) Reconnect the battery negative cable.
(17) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).(18) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
A/C DISCHARGE LINE
DESCRIPTION
The A/C discharge line is the refrigerant line that
goes from the A/C compressor to the A/C condenser.
The A/C discharge line for the 5.9L Diesel engine is
serviced as an assembly with the suction line. The
A/C discharge line has no serviceable parts except
the rubber O-ring seals.
CAUTION: Use only O-ring seals specified for the
vehicle. Failure to use correct O-ring seal will cause
the refrigerant system connection to leak.
The O-ring seals used on the connections are made
from a special type of rubber not affected by R-134a
refrigerant. The O-ring seals must be replaced when-
ever the A/C discharge line is removed and installed.
If the A/C discharge line is found to be leaking or
is damaged, it must be replaced.
REMOVAL
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) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY).
(3) Disconnect the wire harness connector from the
A/C pressure transducer.
(4) Remove the nut that secures the discharge line
fitting to the condenser inlet port (Fig. 15).
(5) Disconnect the discharge line from the con-
denser.
(6) Remove the O-ring seal from the discharge line
fitting and discard.
(7) Install plugs in, or tape over the discharge line
fitting and condenser inlet port.
(8) Remove the bolt that secures the suction/dis-
charge line assembly to the A/C compressor.
Fig. 14 Condenser/Cooling Fan Assembly
1 - LH MOUNTING BOLT
2 - FRONT UPPER CROSSMEMBER
3 - LOWER MOUNTING FLANGE
4 - UPPER MOUNTING SCREW (2)
5 - LOWER MOUNTING SCREW (2)
6 - MOUNTING TABS
7 - CONDENSER COOLING FAN MOTOR
8 - COOLING FAN WIRE CONNECTOR
9 - RH MOUNTING BOLT
24 - 56 PLUMBINGDR
A/C CONDENSER FAN (Continued)

(7) Install plugs in, or tape over the discharge line
fitting and condenser inlet port.
(8) Remove the nut that secures the discharge line
fitting to the A/C compressor.
(9) Disconnect the discharge line from the com-
pressor.
(10) Remove the O-ring seal from the discharge
line fitting and discard.
(11) Install plugs in, or tape over the discharge
line fitting and compressor outlet port.
(12) Remove the discharge line from the engine
compartment.
(13) If necessary, remove the A/C pressure trans-
ducer from the discharge line.
INSTALLATION
INSTALLATION - 5.9L DIESEL ENGINE
(1) If removed, install the A/C pressure transducer
onto the discharge line using a new O-ring seal.
Tighten the transducer securely.
(2) Position the suction/discharge line assembly
into the engine compartment.
(3) Remove the tape or plugs from the suction line
and the accumulator outlet tube fitting.(4) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the accumulator out-
let tube fitting. Use only the specified O-ring as it is
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the A/C compressor in the vehicle.
(5) Connect the suction line to the accumulator
outlet tube (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/REFRIGERANT LINE COU-
PLER - INSTALLATION).
(6) Install the secondary retaining clip onto the
spring-lock coupler that secures the suction line to
the accumulator outlet tube.
(7) Remove the tape or plugs from the suction and
discharge line fittings and the compressor ports.
(8) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the suction and
discharge line fittings. Use only the specified O-rings
as they are made of a special material for the R-134a
system. Use only refrigerant oil of the type recom-
mended for the A/C compressor in the vehicle.
(9) Connect the suction/discharge line assembly to
the compressor.
(10) Install and tighten the bolt that secures the
suction/discharge line assembly to the compressor.
Tighten the bolt to 28 N´m (20 ft. lbs.).
Fig. 17 A/C Discharge Line - 3.7L Shown, 4.7L
Typical
1 - NUT
2 - FRONT UPPER CROSSMEMBER
3 - A/C CONDENSER
4 - NUT (2)
5 - SUCTION LINE
6 - A/C COMPRESSOR
7 - A/C PRESSURE TRANSDUCER
8 - WIRE HARNESS CONNECTOR
9 - A/C DISCHARGE LINE
Fig. 18 A/C Discharge Line - 5.7L Hemi Engine
1 - DISCHARGE LINE
2 - NUT
3 - CONDENSER
4 - NUT
5 - SUCTION LINE
6 - A/C COMPRESSOR
7 - NUT
8 - A/C PRESSURE TRANSDUCER
24 - 58 PLUMBINGDR
A/C DISCHARGE LINE (Continued)

(11) Remove the tape or plugs from the discharge
line fitting and condenser inlet port.
(12) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting. Use only the specified O-ring as it is made of a
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
(13) Connect the discharge line to the condenser
inlet port.
(14) Install and tighten the nut that secures the
discharge line fitting to the condenser. Tighten the
nut to 20 N´m (180 in. lbs.).
(15) Connect the wire harness connector to the A/C
pressure transducer.
(16) Reconnect the battery negative cable.
(17) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(18) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
INSTALLATION - 3.7L/4.7L AND 5.7L HEMI
ENGINE
(1) If removed, install the A/C pressure transducer
onto the discharge line using a new O-ring seal.
Tighten the transducer securely.
(2) Position the discharge line into the engine com-
partment.
(3) Remove the tape or plugs from the discharge
line fitting and the compressor outlet port.
(4) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting. Use only the specified O-ring as it is made of a
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
(5) Connect the discharge line to the compressor.
(6) Install and tighten the nut that secures the
discharge line to the compressor. Tighten the nut to
28 N´m (20 ft. lbs.).
(7) Remove the tape or plugs from the discharge
line fitting and condenser inlet port.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting. Use only the specified O-ring as it is made of a
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.(9) Connect the discharge line to the condenser
inlet port.
(10) Install and tighten the nut that secures the
discharge line fitting to the condenser. Tighten the
nut to 20 N´m (180 in. lbs.).
(11) Connect the wire harness connector to the A/C
pressure transducer.
(12) Reconnect the battery negative cable.
(13) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(14) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
A/C EVAPORATOR
DESCRIPTION
The A/C evaporator is located in the HVAC hous-
ing, behind the instrument panel. The evaporator is
positioned in the HVAC housing so that all air that
enters the housing must pass over the fins of the
evaporator coils before it is distributed through the
system ducts and outlets. However, air passing over
the evaporator fins will only be conditioned when the
compressor is engaged and circulating refrigerant
through the evaporator tubes.
OPERATION
Refrigerant enters the A/C evaporator from the
fixed orifice tube as a low-temperature, low-pressure
mixture of liquid and gas. As air flows over the fins
of the A/C evaporator, the humidity in the air con-
denses on the fins, and the heat from the air is
absorbed by the refrigerant. Heat absorption causes
the refrigerant to boil and vaporize. The refrigerant
becomes a low-pressure gas before it leaves the A/C
evaporator.
The A/C evaporator cannot be repaired and, if
faulty or damaged, it must be replaced.
DRPLUMBING 24 - 59
A/C DISCHARGE LINE (Continued)

DIAGNOSIS AND TESTING - A/C ORIFICE TUBE
WARNING: THE LIQUID LINE BETWEEN THE CON-
DENSER OUTLET AND THE A/C ORIFICE TUBE
CAN BECOME HOT ENOUGH TO BURN THE SKIN.
USE EXTREME CAUTION WHEN PERFORMING THE
FOLLOWING TEST.
NOTE: The A/C orifice tube can be checked for
proper operation using the following procedure.
However, the A/C orifice tube is only serviced as a
part of the liquid line. If the results of this test indi-
cate that the A/C orifice tube is obstructed or miss-
ing, the liquid line must be replaced.
(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
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 A/C ori-
fice tube is in good condition. If there is little or no
detectable temperature differential between the two
ends of the liquid line, the A/C orifice tube is
obstructed or missing and the liquid line must be
replaced.
ACCUMULATOR
DESCRIPTION
The accumulator (Fig. 21) is mounted in the engine
compartment between the evaporator outlet and the
compressor suction port. An integral mounting
bracket is used to secure the accumulator to the dash
panel.
The accumulator cannot be repaired and, if faulty
or damaged, it must be replaced. The rubber O-rings
are available for service replacement.
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 thecanister, 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) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
Fig. 21 Accumulator - Typical
1 - A/C LOW PRESSURE SWITCH (IF EQUIPPED)
2 - PRESSURE SWITCH FITTING
3 - OUTLET TO COMPRESSOR
4 - ANTI-SIPHON HOLE
5 - DESICCANT BAG
6 - OIL RETURN ORIFICE FILTER
7 - VAPOR RETURN TUBE
8 - ACCUMULATOR DOME
9 - O-RING SEAL
10 - INLET FROM EVAPORATOR
DRPLUMBING 24 - 61
A/C ORIFICE TUBE (Continued)

ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY).
(3) Remove the air filter housing cover to gain
access to the accumulator (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM).
(4) Remove the secondary retaining clip from the
spring-lock coupler that secures the suction line to
the accumulator outlet tube (Fig. 22).
(5) Using the proper A/C line disconnect tool, dis-
connect the suction line from the accumulator outlet
tube (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT LINE COUPLER -
REMOVAL).
(6) Remove the O-ring seal from the accumulator
outlet tube fitting and discard.
(7) Install plugs in, or tape over the opened suc-
tion line and the accumulator outlet tube fitting.
(8) Loosen the bolts that secure the accumulator to
the bracket located on the dash panel.
(9) Remove the secondary retaining clip from the
spring-lock coupler that secures the accumulator to
the evaporator outlet tube.
(10) Using the proper A/C line disconnect tool, dis-
connect the accumulator inlet tube fitting from the
evaporator outlet tube (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/REFRIGERANT
LINE COUPLER - REMOVAL).
(11) Remove the O-ring seal from the accumulator
inlet tube fitting and discard.
(12) Install plugs in, or tape over the opened accu-
mulator inlet tube fitting and the evaporator outlet
tube.
(13) Remove the accumulator from the engine com-
partment.
INSTALLATION
NOTE: If the accumulator is being replaced, add 60
milliliters (2 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
(1) Position the accumulator onto the dash panel
bracket in the engine compartment. Do not tighten
the bolts at this time.
(2) Remove the tape or plugs from the accumulator
inlet tube fitting and the evaporator outlet tube.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the accumulator inlet
tube fitting. Use only the specified O-ring as it is
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the A/C compressor in the vehicle.
(4) Connect the accumulator inlet tube fitting to
the evaporator outlet tube (Refer to 24 - HEATING &AIR CONDITIONING/PLUMBING/REFRIGERANT
LINE COUPLER - INSTALLATION).
(5) Install the secondary retaining clip onto the
spring-lock coupler that secures the accumulator
inlet tube fitting to the evaporator outlet tube.
(6) Tighten the accumulator bracket bolts to 4.5
N´m (40 in. lbs.).
(7) Remove the tape or plugs from the suction line
fitting and the accumulator outlet tube.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the accumulator out-
let tube fitting. Use only the specified O-ring as it is
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the A/C compressor in the vehicle.
(9) Connect the suction line to the accumulator
outlet tube (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/REFRIGERANT LINE COU-
PLER - INSTALLATION).
(10) Install the secondary retaining clip onto the
spring-lock coupler that secures the suction line to
the accumulator outlet tube.
(11) Install the air filter housing cover to gain
access to the accumulator (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM).
Fig. 22 A/C Accumulator - Typical
1 - RH INNER FENDER
2 - ACCUMULATOR INLET TUBE
3 - A/C LINE SECONDARY RETAINING CLIP
4 - EVAPORATOR OUTLET TUBE
5 - BOLTS (2)
6 - ACCUMULATOR
7 - SUCTION LINE
8 - A/C LOW PRESSURE SERVICE PORT
9 - A/C LINE SECONDARY RETAINING CLIP
24 - 62 PLUMBINGDR
ACCUMULATOR (Continued)

ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY).
(5) Remove the plastic cover from the condenser
outlet stud.
(6) Remove the nut that secures the liquid line fit-
ting to the condenser outlet (Fig. 26).
(7) Disconnect the liquid line from the condenser.
(8) Remove the seal from the liquid line fitting and
discard.
(9) Install plugs in, or tape over the liquid line fit-
ting and condenser outlet port.
(10) Disengage the liquid lines from the body
retaining clips.
(11) Remove the secondary retaining clip from the
spring-lock coupler that secures the front section of
the liquid line to the rear section of the liquid line.
(12) Using the proper A/C line disconnect tool, dis-
connect the front section of the liquid line from the
rear section of the liquid line (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/REFRIG-
ERANT LINE COUPLER - REMOVAL).
(13) Remove the O-ring seal from the liquid line
fitting and discard.
(14) Install plugs in, or tape over the opened front
liquid line fitting and rear liquid line tube.
(15) Remove the secondary retaining clip from the
spring-lock coupler that secures the liquid line to the
evaporator inlet tube.
(16) Using the proper A/C line disconnect tool, dis-
connect the liquid line from the evaporator inlet tube
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT LINE COUPLER -
REMOVAL).
(17) Remove the O-ring seal from the liquid line
fitting and discard.
(18) Install plugs in, or tape over the opened liquid
line fitting and evaporator inlet tube.
(19) Remove both sections of the liquid line from
the engine compartment.
INSTALLATION
(1) Position both sections of the liquid line into the
engine compartment.
(2) Remove the tape or plugs from the rear liquid
line fitting and the evaporator inlet tube.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the rear liquid line
fitting. Use only the specified O-ring as it is made of
a special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
(4) Connect the liquid line fitting to the evaporator
inlet tube (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/REFRIGERANT LINE COU-
PLER - INSTALLATION).(5) Install the secondary retaining clip onto the
spring-lock coupler that secures the liquid line fitting
to the evaporator inlet tube.
(6) Remove the tape or plugs from the front liquid
line fitting and the rear liquid line tube.
(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the front liquid line
fitting. Use only the specified O-ring as it is made of
a special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
(8) Connect the front liquid line fitting to the rear
liquid line tube (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING/REFRIGERANT LINE
COUPLER - INSTALLATION).
(9) Install the secondary retaining clip onto the
spring-lock coupler that secures the front liquid line
fitting to the rear liquid line tube.
(10) Engage the liquid lines to the body retaining
clips.
(11) Remove the tape or plugs from the liquid line
fitting and condenser outlet port.
(12) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
Use only the specified O-ring as it is made of a spe-
Fig. 26 A/C Liquid Line - Typical
1 - BODY RETAINING CLIP
2 - SECONDARY RETAINING CLIP
3 - BODY RETAINING CLIP
4 - LIQUID LINE (REAR SECTION)
5 - SECONDARY RETAINING CLIP
6 - EVAPORATOR INLET TUBE
7 - A/C CONDENSER
8 - NUT
9 - BODY RETAINING CLIP
10 - LIQUID LINE (FRONT SECTION)
24 - 66 PLUMBINGDR
LIQUID LINE (Continued)

cial material for the R-134a system. Use only refrig-
erant oil of the type recommended for the A/C
compressor in the vehicle.
(13) Connect the liquid line to the condenser outlet
port.
(14) Install and tighten the nut that secures the
liquid line fitting to the condenser. Tighten the nut to
20 N´m (180 in. lbs.).
(15) Install the plastic cover onto the condenser
outlet stud.
(16) If equipped with the diesel engine, install the
passenger side battery tray (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - INSTALLATION).
(17) If equipped with the diesel engine, install the
passenger side battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(18) Reconnect the battery negative cables.
(19) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(20) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
REFRIGERANT
DESCRIPTION
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 a
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 alsolabels 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.
REFRIGERANT LINE COUPLER
DESCRIPTION
Spring-lock type refrigerant line couplers are used
to connect some of the refrigerant lines and other
components to the refrigerant system. These couplers
require a special tool for disengaging the two coupler
halves.
OPERATION
The spring-lock coupler is held together by a garter
spring inside a circular cage on the male half of the
fitting (Fig. 27). When the two coupler halves are
connected, the flared end of the female fitting slips
behind the garter spring inside the cage on the male
fitting. The garter spring and cage prevent the flared
end of the female fitting from pulling out of the cage.
Two O-rings on the male half of the fitting are
used to seal the connection. These O-rings are com-
patible with R-134a refrigerant and must be replaced
with O-rings made of the same material.
Secondary clips are installed over the two con-
nected coupler halves at the factory for added protec-
tion. In addition, some models have a plastic ring
that is used at the factory as a visual indicator to
confirm that these couplers are connected. After the
Fig. 27 Spring-Lock Coupler - Typical
1 - MALE HALF SPRING-LOCK COUPLER
2 - FEMALE HALF SPRING-LOCK COUPLER
3 - SECONDARY CLIP
4 - CONNECTION INDICATOR RING
5 - COUPLER CAGE
6 - GARTER SPRING
7 - COUPLER CAGE
8 - O-RING SEALS
DRPLUMBING 24 - 67
LIQUID LINE (Continued)

coupler is connected, the plastic indicator ring is no
longer required; however, it will remain on the refrig-
erant line near the coupler cage.
REMOVAL
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT - STANDARD
PROCEDURE).
(2) Remove the secondary retaining clip from the
spring-lock coupler.
(3) Fit the proper size A/C line disconnect tool
(Special Tool Kit 7193 or equivalent) over the spring-
lock coupler cage (Fig. 28).
(4) Close the two halves of the A/C line disconnect
tool around the spring-lock coupler.
NOTE: The garter spring may not release if the A/C
line disconnect tool is cocked while pushing it into
the coupler cage opening.
(5) Push the A/C line disconnect tool into the open
side of the coupler cage to expand the garter spring.
Once the garter spring is expanded and while still
pushing the disconnect tool into the open side of the
coupler cage, pull on the refrigerant line attached to
the female half of the coupler fitting until the flange
on the female fitting is separated from the garter
spring and cage on the male fitting within the dis-
connect tool.
(6) Open and remove the A/C line disconnect tool
from the disconnected spring-lock coupler.(7) Complete the separation of the two halves of
the coupler fitting. Inspect the O-ring seals and mat-
ing areas for damage.
INSTALLATION
(1) Check to make sure that the garter spring is
located within the cage of the male coupler fitting,
and that the garter spring is not damaged.
(a) If the garter spring is missing, install a new
spring by pushing it into the coupler cage opening.
(b) If the garter spring is damaged, remove it
from the coupler cage with a small wire hook (DO
NOT use a screwdriver) and install a new garter
spring.
(2) Clean any dirt or foreign material from both
halves of the coupler fitting.
CAUTION: Use only the specified O-rings as they
are made of a special material for the R-134a sys-
tem. The use of any other O-rings may allow the
connection to leak intermittently during vehicle
operation.
(3) Install new O-rings on the male half of the cou-
pler fitting.
(4) Lubricate the male fitting and O-rings, and the
inside of the female fitting with clean R-134a refrig-
erant oil. Use only refrigerant oil of the type recom-
mended for the compressor in the vehicle.
(5) Fit the female half of the coupler fitting over
the male half of the fitting.
(6) Push together firmly on the two halves of the
coupler fitting until the garter spring in the cage on
the male half of the fitting snaps over the flanged
end on the female half of the fitting.
(7) Make sure that the spring-lock coupler is fully
engaged by trying to separate the two coupler halves.
This is done by pulling the refrigerant lines on either
side of the coupler away from each other.
(8) Install the secondary retaining clip over the
spring-lock coupler cage.
REFRIGERANT OIL
DESCRIPTION
The refrigerant oil used in R-134a refrigerant sys-
tems 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
contains a different additive package. Two different
type of A/C compressors are used in this vehicle
depending on engine application. Both compressors
are designed to use a PAG refrigerant oil. However,
the PAG oil type differs between the two compressor
Fig. 28 Refrigerant Line Spring-Lock Coupler
Disconnect
24 - 68 PLUMBINGDR
REFRIGERANT LINE COUPLER (Continued)

(2) Disconnect the refrigerant lines from the A/C
compressor. Cap open lines to prevent moisture from
entering the system.
(3) Remove the A/C compressor from the vehicle.
(4) From the suction and discharge ports on the
A/C compressor, drain the lubricant from the old A/C
compressor into a clean container.
(5) From the suction and discharge ports on the
A/C compressor, drain the lubricant from the new
A/C compressor into a clean container.
(6) Install new lubricant back into the new A/C
compressor in the amount measured from the used
compressor, plus adding any amount of lubricant lost
when the refrigerant system was reclaimed.
(7) Install the A/C compressor and connect the
refrigerant lines. Then evacuate and charge refriger-
ant system.
SERVICE PORT VALVE CORE
DESCRIPTION
A/C SERVICE PORT VALVE CORES
The A/C service port valve cores are serviceable
items. The A/C pressure transducer is mounted on
the high side service port which is located on the dis-
charge line near the A/C compressor. The low side
service port is located on the suction line near the
accumulator outlet tube.
REMOVAL - SERVICE PORT VALVE CORES
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM 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 the protective cap from the low side
service port as necessary.
(2) Remove the A/C pressure transducer from the
high side service port as necessary (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS/A/C
PRESSURE TRANSDUCER - REMOVAL).
(3) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT - STANDARD
PROCEDURE).
(4) Using a standard Schrader-type valve core tool,
remove the valve core from the service ports as
required.
(5) Install a plug in or tape over the opened ser-
vice port(s).
INSTALLATION
(1) Lubricate the A/C service port valve core with
clean refrigerant oil prior to installation. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
(2) Remove the tape or plug from the A/C service
port.
CAUTION: A valve core that is not fully seated in
the A/C service port can result in damage to the
valve during refrigerant system evacuation and
charge. Such damage may result in a loss of sys-
tem refrigerant while uncoupling the charge adapt-
ers.
(3) Using a standard Schrader-type valve core tool,
install and tighten the replacement valve core into
the A/C service ports as required.
(4) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(5) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
(6) Install the A/C pressure transducer to the high
side service port as necessary (Refer to 24 - HEAT-
ING & AIR CONDITIONING/CONTROLS/A/C
PRESSURE TRANSDUCER - INSTALLATION).
(7) Install the protective cap onto the A/C service
ports as required.
SUCTION LINE
DESCRIPTION
The suction line is the refrigerant line that goes
from the evaporator outlet tube to the compressor
inlet port. The suction line for the 5.9L Diesel engine
is only serviced as an assembly with the discharge
line. The suction line has no serviceable parts except
the rubber O-rings. If the suction line is found to be
leaking or is damaged, it must be replaced.
REMOVAL
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) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
24 - 70 PLUMBINGDR
REFRIGERANT OIL (Continued)