system 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)

(10) Connect the discharge line to the condenser
inlet port.
(11) Install and tighten the nut that secures the
discharge line fitting to the condenser. Tighten the
nut to 20 N´m (180 in. lbs.).
(12) Install the plastic cover onto the condenser
inlet stud.
(13) Reconnect the battery negative cable.
(14) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(15) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
A/C CONDENSER FAN
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) 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) Remove the nut that secures the discharge line
fitting to the condenser inlet port (Fig. 13).
(4) Disconnect the discharge line from the con-
denser.
(5) Remove the seal from the discharge line fitting
and discard.
(6) Install plugs in, or tape over the discharge line
fitting and condenser inlet port.
(7) Remove the plastic cover from the condenser
outlet stud.
(8) Remove the nut that secures the liquid line fit-
ting to the condenser outlet.
(9) Disconnect the liquid line from the condenser.
(10) Remove the seal from the liquid line fitting
and discard.
(11) Install plugs in, or tape over the liquid line
fitting and condenser inlet port.
(12) Disconnect the wire harness connector from
the condenser cooling fan motor (Fig. 14).
(13) Remove the two bolts that secure the con-
denser to the front upper crossmember.(14) Remove the condenser/cooling fan assembly
from the vehicle.
(15) Place the condenser/cooling fan assembly on a
flat work area and remove the four screws that
secure the cooling fan to the condenser.
(16) Separate the cooling fan from the condenser.
INSTALLATION - 3.7, 4.7 and 5.7L ENGINES
(1) Position the condenser cooling fan onto the A/C
condenser.
(2) Install and tighten the four screws that secure
the condenser cooling fan to the A/C condenser.
Tighten the screws to 2.2 N´m (20 in. lbs.).
(3) Carefully position the condenser/cooling fan
assembly into the engine compartment.
(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.
Fig. 13 A/C Discharge Line - 3.7L Shown, 4.7L/5.7L
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
DRPLUMBING 24 - 55
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)

(9) Disconnect the suction/discharge line assembly
from the A/C compressor.
(10) Remove the O-ring seals from the suction and
discharge line fittings and discard.
(11) Install plugs in, or tape over all of the opened
refrigerant line fittings and the compressor ports.
(12) Remove the secondary retaining clip from the
spring-lock coupler that secures the suction line to
the accumulator outlet tube (Fig. 16).
(13) Using the proper A/C line disconnect tool, dis-
connect the suction line from the accumulator outlet
tube fitting (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/REFRIGERANT LINE COU-
PLER - REMOVAL).
(14) Remove the O-ring seal from the accumulator
outlet tube fitting and discard.
(15) Install plugs in, or tape over the opened suc-
tion line and the accumulator outlet tube fitting.
(16) Remove the suction/discharge line assembly
from the engine compartment.
(17) If necessary, remove the A/C pressure trans-
ducer from the discharge line.
REMOVAL - 3.7L/4.7L AND 5.7L HEMI 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 (Fig. 17) or (Fig. 18),
depending on application.
(4) Remove the nut that secures the discharge line
fitting to the condenser inlet port.
(5) Disconnect the discharge line from the con-
denser.
(6) Remove the O-ring seal from the discharge line
fitting and discard.
Fig. 15 A/C Discharge Line - 5.9L Diesel Engine
1 - CONDENSER
2 - NUT
3 - LIQUID LINE
4 - NUT
5 - PRESSURE TRANSDUCER WIRE CONNECTOR
6 - A/C COMPRESSOR
7 - BOLT
8 - SUCTION/DISCHARGE LINE ASSEMBLY
Fig. 16 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
DRPLUMBING 24 - 57
A/C DISCHARGE LINE (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)

REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).
(2) Disassemble the HVAC housing to access the
A/C evaporator (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/HVAC HOUSING -
DISASSEMBLY).
(3) Remove the evaporator temperature sensor
probe from the A/C evaporator.
(4) Lift the A/C evaporator out of the HVAC hous-
ing (Fig. 19).
INSTALLATION
NOTE: If the A/C evaporator 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) Install the A/C evaporator into the HVAC hous-
ing. Make sure that the evaporator drain is clean
and unrestricted and that the evaporator deflector
shield is installed.
(2) Install the evaporator temperature sensor
probe into the A/C evaporator.
(3) Assemble the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY).
(4) Install the HVAC housing (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).
A/C ORIFICE TUBE
DESCRIPTION
The fixed A/C orifice tube (Fig. 20) is installed in
the liquid line between the outlet of the condenser
and the inlet of the evaporator. The A/C orifice tube
is only serviced as an part of the liquid line.
OPERATION
The fixed A/C orifice tube is used to meter the flow
of liquid refrigerant into the evaporator coil. The
high-pressure liquid refrigerant from the condenser
expands into a low-pressure liquid as it passes
through the metering orifice and diffuser screen of
the A/C orifice tube.
The A/C orifice tube is not serviceable. The A/C ori-
fice tube cannot be repaired and, if faulty or plugged,
it must be replaced as part of the liquid line.
Fig. 19 A/C Evaporator - Typical
1 - PASSENGER SIDE BLEND DOOR LEVER
2 - PASSENGER SIDE BLEND DOOR
3 - EVAPORATOR TEMPERATURE SENSOR WIRE
4 - HVAC HOUSING
5 - A/C EVAPORATOR
6 - EVAPORATOR TEMPERATURE SENSOR PROBE
7 - DRIVER SIDE BLEND DOOR
8 - DRIVER SIDE BLEND DOOR LEVER
Fig. 20 Fixed A/C Orifice Tube - Typical
1 - DIFFUSER SCREEN
2 - O-RING SEALS
3 - INLET FILTER SCREEN
4 - ORIFICE
24 - 60 PLUMBINGDR
A/C EVAPORATOR (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)

(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).
HEATER CORE
DESCRIPTION
The heater core is located in the HVAC housing,
behind the instrument panel. It is a heat exchanger
made of rows of tubes and fins.
OPERATION
Engine coolant is circulated through the heater
hoses to the heater core at all times. As the coolant
flows through the heater core, heat is removed from
the engine and 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 regulating the amount of air flowing through the
heater core within the HVAC housing. 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
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: Disassembly of the HVAC housing is not
required to remove heater core.
(1) Remove the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).(2) Remove the foam seal from the heater core
tubes.
(3) If equipped with the Dual Zone system, remove
the linkage rod from the actuator levers to gain
access to the heater core (Fig. 23).
(4) Remove the two screws that secure the heater
core tube bracket to the HVAC housing.
(5) Remove the heater core tube bracket.
(6) Pull the heater core out of the HVAC housing.
(7) Inspect all foam seals and repair or replace
them as required.
INSTALLATION
(1) Install the heater core into the HVAC housing.
(2) Position the heater core tube bracket onto the
HVAC housing.
(3) Install the two screws that secure the heater
core bracket to the HVAC housing. Tighten the
screws to 2.2 N´m (20 in. lbs.).
(4) If equipped with the Dual Zone system, install
the linkage rod onto the actuator levers.
(5) Install the foam seal onto the heater core
tubes.
(6) Install the HVAC housing (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).
Fig. 23 Heater Core ± Dual Zone Shown, Single
Zone Typical
1 - SCREWS
2 - TUBE BRACKET
3 - HEATER CORE
4 - LINKAGE ROD (IF EQUIPPED)
DRPLUMBING 24 - 63
ACCUMULATOR (Continued)