DODGE RAM 2001 Service Repair Manual

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.
When installing a refrigerant line, avoid sharp
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.
When disconnecting a refrigerant fitting, use a
wrench on both halves of the fitting. This will pre-
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 ofrefrigerant 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:
²All 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.
²Unified 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.
24 - 42 PLUMBINGBR/BE
PLUMBING (Continued)

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 foreign material is
present in the refrigerant system.
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.
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS
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 air conditioning system is not cooling prop-
erly, determine if the refrigerant system is fully-
charged. (Refer to 24 - HEATING & AIR
CONDITIONING - DIAGNOSIS AND TESTING -
A/C PERFORMANCE) If the refrigerant system is
low or empty; a leak at a refrigerant line, connector
fitting, component, or component seal is likely.
An electronic leak detector designed for R-134a
refrigerant, or a fluorescent R-134a leak detection
dye and a black light are recommended for locating
and confirming refrigerant system leaks. Refer to the
operating instructions supplied by the equipment
manufacturer for proper care and use of this equip-
ment.
An oily residue on or near refrigerant system lines,
connector fittings, components, or component seals
can indicate the general location of a possible refrig-
erant leak. However, the exact leak location should
be confirmed with an electronic leak detector prior to
component repair or replacement.
To detect a leak in the refrigerant system with an
electronic leak detector, perform one of the following
procedures:
SYSTEM EMPTY
(1) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(2) Connect and dispense 0.283 kilograms (0.625
pounds or 10 ounces) of R-134a refrigerant into the
evacuated refrigerant system. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE - REFRIGERANT SYSTEM
CHARGE)
(3) Position the vehicle in a wind-free work area.
This will aid in detecting small leaks.
(4) With the engine not running, use a electronic
R-134a leak detector and search for leaks. Because
R-134a refrigerant is heavier than air, the leak detec-
tor probe should be moved slowly along the bottom
side of all refrigerant lines, connector fittings and
components.
(5) To inspect the evaporator coil for leaks, insert
the electronic leak detector probe into the center
instrument panel outlet. Set the blower motor switch
to the lowest speed position, and the mode control
switch in the recirculation mode.
SYSTEM LOW
(1) Position the vehicle in a wind-free work area.
This will aid in detecting small leaks.
(2) Bring the refrigerant system up to operating
temperature and pressure. This is done by allowing
the engine to run with the air conditioning system
turned on for five minutes.
(3) With the engine not running, use a electronic
R-134a leak detector and search for leaks. Because
R-134a refrigerant is heavier than air, the leak detec-
tor probe should be moved slowly along the bottom
side of all refrigerant lines, connector fittings and
components.
(4) To inspect the evaporator coil for leaks, insert
the electronic leak detector probe into the center
instrument panel outlet. Set the blower motor switch
to the lowest speed position, and the mode control
switch in the recirculation mode.
STANDARD PROCEDURE - A/C LINE
COUPLERS
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)
REMOVAL
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
BR/BEPLUMBING 24 - 43
PLUMBING (Continued)

TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(2) Remove the secondary clip from the spring-lock
coupler.
(3) Fit the proper size A/C line disconnect tool
(Special Tool Kit 7193) over the spring-lock coupler
cage (Fig. 2).
(4) Close the two halves of the A/C line disconnect
tool around the spring-lock coupler.
(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.
INSTALLATION
(1) Check to ensure 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.(3) Install new O-rings on the male half of the cou-
pler 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.
(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) Ensure 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) Reinstall the secondary clip over the spring-
lock coupler cage.
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 recovery/recycling/charging equipment.
Refer to the operating instructions supplied by the
equipment manufacturer for proper care and use of
this equipment.
A manifold gauge set may be needed with some
recovery/recycling/charging equipment (Fig. 3). 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.
Fig. 2 REFRIGERANT LINE SPRING-LOCK
COUPLER DISCONNECT
24 - 44 PLUMBINGBR/BE
PLUMBING (Continued)

LOW PRESSURE GAUGE HOSE The low pressure
hose (Blue with Black stripe) attaches to the suction
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
discharge line between the compressor and the con-
denser inlet.
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-
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 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) 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.
(3) Close all of the valves, and turn off the charg-
ing station vacuum pump.
(4) 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)
Fig. 3 MANIFOLD GAUGE SET - 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
BR/BEPLUMBING 24 - 45
PLUMBING (Continued)

STANDARD PROCEDURE - REFRIGERANT
SYSTEM 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.
SPECIFICATIONS
SPECIFICATIONS
The R-134a refrigerant system charge capacity for
this vehicle is: 0.907 kilograms (32 ounces).
A/C COMPRESSOR
DESCRIPTION - A/C COMPRESSOR
The air conditioning system uses a Sanden
SD7H15 seven cylinder, reciprocating wobble plate-
type compressor on all models. This compressor has a
fixed displacement of 150 cubic centimeters (9.375
cubic inches), 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 com-
pressor.
DESCRIPTION - HIGH PRESSURE RELIEF
VALVE
A high pressure relief valve is located on the com-
pressor cylinder head, which is at 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-
nents, caused by condenser air flow restriction or an
overcharge of refrigerant.
OPERATION - A/C COMPRESSOR
The compressor is driven by the engine through an
electric clutch, drive pulley and belt arrangement.
The compressor is lubricated by refrigerant oil that iscirculated 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 with
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 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
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
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
24 - 46 PLUMBINGBR/BE
PLUMBING (Continued)

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 pulley 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, recover, evacuate, and
recharge the refrigerant system. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE - REFRIGERANT RECOVERY)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - REFRIG-
ERANT SYSTEM EVACUATE) (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM 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, replace the accumulator. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/AC-
CUMULATOR - REMOVAL) Check the refrigerant oil
level and the refrigerant system charge. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
REFRIGERANT OIL - STANDARD PROCEDURE -
REFRIGERANT OIL LEVEL) (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - SPECI-
FICATIONS - CHARGE CAPACITY) If the liquid
slugging condition continues following accumulator
replacement, replace the compressor.
(7) If the noise continues, replace the compressor
and repeat Step 1.
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
Cooling for the procedures.
(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. 4) or (Fig. 5).
(7) Remove the a/c compressor from the mounting
bracket.
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)
NOTE: If a replacement compressor 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)
BR/BEPLUMBING 24 - 47
A/C COMPRESSOR (Continued)

(3) Install the serpentine drive belt. Refer to Cool-
ing for the procedures.
(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)
A/C CONDENSER
DESCRIPTION
The condenser is located in the air flow in front of
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 itsheat to the air passing over the condenser fins, thus
causing the refrigerant to change to a liquid state.
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.
Fig. 4 COMPRESSOR REMOVE/INSTALL - GASOLINE ENGINE
1 - BRACKET
2 - A/C COMPRESSOR
3 - BOLT AND WASHER4 - BRACE
5 - BOLT
24 - 48 PLUMBINGBR/BE
A/C COMPRESSOR (Continued)

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)
(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-
PLER) Install plugs in, or tape over all of the opened
refrigerant line fittings.
(5) On gasoline engine models:(a) Remove the two screws that secure the con-
denser upper mounting brackets to the outside of
the upper radiator crossmember (Fig. 6).
(b) Tilt the condenser away from the engine
compartment far enough to grasp the top of the
condenser with both hands.
(c) Lift the condenser far enough to remove the
two lower condenser locators from the isolators in
the holes of the lower crossmember.
(d) Remove the condenser from the vehicle.
(6) On diesel engine models:
(a) Remove the two screws that secure the
brackets on the passenger side end of the con-
denser to the charge air cooler (Fig. 7).
(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.
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)
Fig. 5 COMPRESSOR REMOVE/INSTALL - DIESEL
ENGINE
1 - ENGINE
2 - BRACKET
3 - A/C COMPRESSOR
4 - BOLTS
Fig. 6 CONDENSER REMOVE/INSTALL - GASOLINE
ENGINE
1 - CONDENSER
2 - LOCATOR
3 - ISOLATOR
4 - SCREW
BR/BEPLUMBING 24 - 49
A/C CONDENSER (Continued)

(1) On gasoline engine models:
(a) Insert the two lower condenser locators into
the isolators in the holes of the lower crossmember.
(b) Tilt the condenser up towards the engine
compartment far enough to align the upper mount-
ing bracket holes with the holes in the upper radi-
ator crossmember.
(c) Install the two screws that secure the con-
denser upper mounting brackets to the outside of
the upper radiator crossmember. Tighten the
mounting screws to 10.5 N´m (95 in. lbs.).
(2) 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.).
(3) 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)
(4) 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.).
(5) Check that all of the condenser and radiator
air seals are in their proper locations.(6) Connect the battery negative cable.
(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)
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)
SUCTION AND DISCHARGE
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.
(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) On models with a gasoline engine, remove the
nut that secures the refrigerant line support bracket
to the stud on the compressor mounting bracket.
(7) Remove the bolt that secures the refrigerant
line manifold to the compressor (Fig. 8) or (Fig. 9).
Install plugs in, or tape over all of the opened refrig-
erant line fittings.
Fig. 7 CONDENSER REMOVE/INSTALL - DIESEL
ENGINE
1 - CHARGE AIR COOLER
2 - NUT
3 - CONDENSER
4 - SCREW
24 - 50 PLUMBINGBR/BE
A/C CONDENSER (Continued)

(8) Remove the suction and discharge line assem-
bly 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 -
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.).
Fig. 8 SUCTION AND DISCHARGE LINE REMOVE/INSTALL - GASOLINE ENGINE
1 - CLIP
2 - ACCUMULATOR
3 - BOLT
4 - MANIFOLD
5 - A/C HIGH PRESSURE SWITCH
6 - WIRE HARNESS CONNECTOR
7 - CONDENSER8 - NUT
9 - DISCHARGE LINE
10 - SUCTION LINE
11 - NUT
12 - STUD
Fig. 9 SUCTION AND DISCHARGE LINE REMOVE/
INSTALL - DIESEL ENGINE
1 - DISCHARGE LINE (TO CONDENSER)
2 - COMPRESSOR
3 - BOLT
4 - MANIFOLD
5 - SUCTION LINE (FROM ACCUMULATOR)
6 - A/C HIGH PRESSURE SWITCH
BR/BEPLUMBING 24 - 51
SUCTION AND DISCHARGE LINE (Continued)