ECU DODGE RAM 2002 Service Repair Manual

(3) Be certain that the blower motor seal is
installed on the blower motor housing (Fig. 5).
(4) Install the blower motor and wheel assembly,
and cover in the HVAC housing with three mounting
screws. Tighten the mounting screws to 2.2 N´m (20
in. lbs.).
(5) Plug the blower motor wire harness connector
into the HVAC housing wire harness.
(6) Install the blower motor wire harness into the
wire harness retainer.
(7) Connect the blower motor cooling tube to the
nipple on the blower motor housing.
(8) Connect the battery negative cable.
DEFROSTER DUCTS
REMOVAL - DEFROSTER AND DEMISTER
DUCTS
The defroster duct and the main demister duct are
a single molded plastic unit. The defroster outlet
grilles are heat-staked to the defroster outlets and
cannot be serviced separately. The demister tubes on
each end of the main demister duct are only serviced
in the instrument panel assembly.
(1) Remove the instrument panel top cover from
the instrument panel(Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL TOP COVER
- REMOVAL).
(2) Remove the screws that secure the defroster
and demister ducts to the instrument panel brackets
(Fig. 6).
(3) Disengage the demister tubes from each end of
the main demister duct.
(4) Remove the defroster and demister duct unit
from the instrument panel.
REMOVAL - DEFROSTER AND DEMISTER
DUCT ADAPTER
(1) Roll the instrument panel assembly down, but
do not remove it from the vehicle(Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL).
(2) Using a trim stick or another suitable wide
flat-bladed tool, gently pry at the perimeter edges of
the defroster and demister duct adapter to release
the snap features from the top of the HVAC housing
(Fig. 7).
(3) Remove the defroster and demister duct
adapter from the top of the HVAC housing.
INSTALLATION - DEFROSTER AND DEMISTER
DUCTS
(1) Place the defroster and demister duct unit in
position.
(2) Engage the demister tubes with each end of
the main demister duct.
(3) Install the screws that secure the defroster and
demister ducts to the instrument panel brackets.
Tighten the mounting screws to 2.2 N´m (20 in. lbs.).
(4) Install the instrument panel top cover on the
instrument panel(Refer to 23 - BODY/INSTRUMENT
PANEL/INSTRUMENT PANEL TOP COVER -
INSTALLATION).
INSTALLATION - DEFROSTER AND DEMISTER
DUCT ADAPTER
(1) Snap the defroster and demister duct adapter
from the top of the HVAC housing.
Fig. 4 BLOWER MOTOR WHEEL REMOVE/INSTALL
1 - BLOWER MOTOR WHEEL
2 - RETAINER CLIP
Fig. 5 BLOWER MOTOR SEAL
1 - BLOWER MOTOR SEAL
BR/BEDISTRIBUTION 24 - 33
BLOWER MOTOR (Continued)

(1) Disconnect and isolate the battery negative
cable.
(2) If the vehicle is not equipped with air condi-
tioning, go to Step 6. If the vehicle is equipped with
air conditioning, recover the refrigerant from the sys-
tem. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(3) Remove the instrument panel from the vehicle.
Refer to Instrument Panel System for the procedures.
(4) Disconnect the liquid line refrigerant line fit-
ting from the evaporator inlet tube. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - A/C LINE COUPLERS)
Install plugs in, or tape over all of the opened refrig-
erant line fittings.
(5) Remove the accumulator. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/ACCU-
MULATOR - REMOVAL) Install plugs in, or tape
over all of the opened refrigerant line fittings.
(6) Drain the engine cooling system(Refer to 7 -
COOLING - STANDARD PROCEDURE) and (Refer
to 7 - COOLING - STANDARD PROCEDURE).
(7) Disconnect the heater hoses from the heater
core tubes. Refer to Cooling for the procedures.
Install plugs in, or tape over the opened heater core
tubes.
(8) Remove the Powertrain Control Module (PCM)
from the dash panel and set it aside, but do not
unplug the PCM wire harness connectors. Refer to
Electronic Control Modules for the procedures.
(9) Remove the nuts from the HVAC housing
mounting studs on the engine compartment side of
the dash panel.
(10) Remove the nuts that secure the HVAC hous-
ing to the mounting studs on the passenger compart-
ment side of the dash panel (Fig. 8).
(11) Pull the HVAC housing rearward far enough
for the mounting studs and the evaporator conden-
sate drain tube to clear the dash panel holes.
(12) Remove the HVAC housing from the vehicle.
REMOVAL - HVAC HOUSING INLET BAFFLE
(1) Remove the HVAC housing from the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL)
(2) Slide the HVAC housing inlet baffle (Fig. 9) all
the way to one side of the cowl plenum opening.
(3) Pull downwards sharply and firmly on the
opposite side of the HVAC housing inlet baffle to dis-
engage the snap features from the cowl plenum open-
ing.
(4) Remove the HVAC housing inlet baffle from the
cowl plenum panel.DISASSEMBLY
(1) Place the HVAC housing upside down on a
work bench.
(2) Remove the screw that secures the floor duct to
the bottom of the HVAC housing and slide the floor
duct off of the center heat duct adaptor.
(3) Unsnap the center heat duct adaptor from the
bottom of the HVAC housing and remove the screw
that was hidden by the adaptor.
(4) Remove the remaining screws on the bottom of
the HVAC housing that secure the two housing
halves together.
Fig. 8 HVAC HOUSING REMOVE/INSTALL
1 - BODY ASSEMBLY
2 - HVAC HOUSING
Fig. 9 HVAC HOUSING INLET BAFFLE REMOVE/
INSTALL
1 - RIGHT A-PILLAR
2 - INLET BAFFLE
3 - COWL PLENUM OPENING
BR/BEDISTRIBUTION 24 - 35
HVAC HOUSING (Continued)

(5) Place the HVAC housing right side up on the
work bench.
(6) Separate the top half of the HVAC housing
from the bottom half and set it aside.
ASSEMBLY
(1) Position the top half of the HVAC housing over
the bottom half. Be certain that the mode door pivot
pins are properly inserted in their pivot holes.
(2) Place the HVAC housing upside down on the
work bench.
(3) Install and tighten the screws on the bottom of
the HVAC housing that secure the two housing
halves together. Tighten the screws to 2.2 N´m (20 in.
lbs.).
(4) Snap the center heat duct adaptor onto the bot-
tom of the HVAC housing.
(5) Slide the floor duct onto the center heat duct
adaptor and secure it with a screw to the bottom of
the HVAC housing. Tighten the mounting screw to
2.2 N´m (20 in. lbs.).
INSTALLATION
(1) Position the HVAC housing to the dash panel.
Be certain that the evaporator condensate drain tube
and the housing mounting studs are inserted into
their correct mounting holes.
(2) Install the nuts that secure the HVAC housing
to the mounting studs on the passenger compartment
side of the dash panel. Tighten the nuts to 4.5 N´m
(40 in. lbs.).
(3) Install and tighten the nuts onto the HVAC
housing mounting studs on the engine compartment
side of the dash panel. Tighten the nuts to 7 N´m (60
in. lbs.).
(4) Unplug or remove the tape from the heater
core tubes. Connect the heater hoses to the heater
core tubes and fill the engine cooling system(Refer to
7 - COOLING - STANDARD PROCEDURE) and
(Refer to 7 - COOLING - STANDARD PROCE-
DURE).
(5) If the vehicle is not equipped with air condi-
tioning, go to Step 10. If the vehicle is equipped with
air conditioning, install the accumulator. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
ACCUMULATOR - INSTALLATION) Connect the
accumulator inlet tube coupler to the evaporator out-
let tube. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
A/C LINE COUPLERS)
(6) Unplug or remove the tape from the liquid line
and the evaporator inlet tube fittings. Connect the
liquid line coupler to the evaporator inlet tube. (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE - A/C LINE COU-
PLERS)(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)
(9) Reinstall the PCM to the dash panel. Refer to
Electronic Control Modules for the procedures.
(10) Reinstall the instrument panel in the vehi-
cle(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY -
INSTALLATION).
(11) Connect the battery negative cable.
(12) Start the engine and check for proper opera-
tion of the heating and air conditioning systems.
INSTALLATION - HVAC HOUSING INLET
BAFFLE
(1) Install the HVAC housing inlet baffle in the
cowl plenum panel.
(2) Slide the HVAC housing inlet baffle to engage
the snap features.
(3) Make certain that the snap features on each
side of the adapter are fully engaged with the sides
of the plenum panel opening. This must be a water
tight connection to prevent leaks.
(4) Install the HVAC housing in the vehicle. (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION/HVAC HOUSING - INSTALLATION)
INSTRUMENT PANEL
DEMISTER DUCTS
REMOVAL
The defroster duct and the main demister duct are
a single molded plastic unit. The defroster outlet
grilles are heat-staked to the defroster outlets and
cannot be serviced separately. The demister tubes on
each end of the main demister duct are only serviced
in the instrument panel assembly. (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
DEFROSTER DUCTS - REMOVAL)
INSTALLATION
The defroster duct and the main demister duct are
a single molded plastic unit. The defroster outlet
grilles are heat-staked to the defroster outlets and
cannot be serviced separately. The demister tubes on
each end of the mail demister duct are only serviced
in the instrument panel assembly(Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
DEFROSTER DUCTS - INSTALLATION).
24 - 36 DISTRIBUTIONBR/BE
HVAC HOUSING (Continued)

PLUMBING
TABLE OF CONTENTS
page page
PLUMBING
DESCRIPTION..........................40
OPERATION............................41
WARNING..............................42
CAUTION..............................42
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS.......................43
STANDARD PROCEDURE
STANDARD PROCEDURE - A/C LINE
COUPLERS...........................44
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT...........45
STANDARD PROCEDURE - REFRIGERANT
RECOVERY...........................45
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE....................46
STANDARD PROCEDURE - REFRIGERANT
SYSTEM CHARGE......................46
SPECIFICATIONS........................46
A/C COMPRESSOR
DESCRIPTION..........................46
OPERATION............................46
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
COMPRESSOR........................47
REMOVAL..............................47
INSTALLATION..........................48
A/C CONDENSER
DESCRIPTION..........................49
OPERATION............................49
REMOVAL..............................49
INSTALLATION..........................50
SUCTION AND DISCHARGE LINE
REMOVAL..............................51
INSTALLATION..........................52LIQUID LINE
REMOVAL..............................52
INSTALLATION..........................52
A/C EVAPORATOR
DESCRIPTION..........................53
OPERATION............................53
REMOVAL..............................53
INSTALLATION..........................53
A/C ORIFICE TUBE
DESCRIPTION..........................54
OPERATION............................54
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FIXED
ORIFICE TUBE.........................54
REMOVAL..............................54
INSTALLATION..........................54
ACCUMULATOR
DESCRIPTION..........................55
OPERATION............................55
REMOVAL..............................55
INSTALLATION..........................55
HEATER CORE
DESCRIPTION..........................56
OPERATION............................56
REMOVAL..............................56
INSTALLATION..........................56
REFRIGERANT
DESCRIPTION..........................56
OPERATION............................57
REFRIGERANT OIL
DESCRIPTION..........................57
OPERATION............................57
STANDARD PROCEDURE
STANDARD PROCEDURE - REFRIGERANT
OIL LEVEL............................57
PLUMBING
DESCRIPTION - A/C LINE COUPLERS
Spring-lock type refrigerant line couplers are used
to connect many of the refrigerant lines and other
components to the refrigerant system. These couplers
require a special tool for disengaging the two coupler
halves.
DESCRIPTION- REFRIGERANT LINES
The refrigerant lines and hoses are used to carry
the refrigerant between the various air conditioning
system components. A barrier hose design with a
nylon tube, which is sandwiched between rubber lay-
ers, is used for the R-134a air conditioning system on
this vehicle. This nylon tube helps to further contain
the R-134a refrigerant, which has a smaller molecu-
lar structure than R-12 refrigerant. The ends of the
refrigerant hoses are made from lightweight alumi-
num or steel, and commonly use braze-less fittings.
24 - 40 PLUMBINGBR/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 operating temperature,
and any other special conditions. Noises that develop
during air conditioning operation can often be mis-
leading. 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 before beginning this procedure(Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
DIAGNOSIS AND TESTING).
(1) Select a quiet area for testing. Duplicate the
complaint conditions as much as possible. Switch the
compressor on and off several times to clearly iden-
tify the compressor noise. Listen to the compressor
while the clutch is engaged and disengaged. Probe
the compressor with an engine stethoscope or a long
screwdriver with the handle held to your ear to bet-
ter localize the source of the noise.
(2) Loosen all of the compressor mounting hard-
ware and retighten. Tighten the compressor clutch
mounting nut. Be certain that the clutch coil is
mounted securely to the compressor, and that the
clutch plate and pulley are properly aligned and have
the correct air gap. (Refer to 24 - HEATING & AIRCONDITIONING/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-
BR/BEPLUMBING 24 - 47
A/C COMPRESSOR (Continued)

TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the serpentine drive belt(Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL), (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - REMOVAL) or (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Unplug the compressor clutch coil wire harness
connector.
(5) Remove the bolt that secures the refrigerant
line manifold to the compressor. Install plugs in, or
tape over all of the opened refrigerant line fittings.
(6) Remove the four bolts that secure the compres-
sor to the mounting bracket (Fig. 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)
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)

(1) Install the compressor to the mounting bracket.
Tighten the four mounting bolts to 24 N´m (210 in.
lbs.).
(2) Remove the tape or plugs from all of the
opened refrigerant line fittings. Install the suction
and discharge line manifold to the compressor. (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/A/C SUCTION AND DISCHARGE LINE -
INSTALLATION)
(3) Install the serpentine drive belt(Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION), (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - INSTALLATION) or
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - INSTALLATION).
(4) Plug in the compressor clutch coil wire harness
connector.
(5) Connect the battery negative cable.
(6) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
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 its
heat 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.
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).
Fig. 5 COMPRESSOR REMOVE/INSTALL - DIESEL
ENGINE
1 - ENGINE
2 - BRACKET
3 - A/C COMPRESSOR
4 - BOLTS
BR/BEPLUMBING 24 - 49
A/C COMPRESSOR (Continued)

(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)
(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)
Fig. 6 CONDENSER REMOVE/INSTALL - GASOLINE
ENGINE
1 - CONDENSER
2 - LOCATOR
3 - ISOLATOR
4 - SCREW
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) 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. 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
BR/BEPLUMBING 24 - 51
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.).
(3) Install the refrigerant line manifold to the com-
pressor. Tighten the mounting bolt to 22 N´m (200 in.
lbs.).
(4) On models with a gasoline engine, install the
nut that secures the refrigerant line support bracket
to the stud on the compressor mounting bracket.
Tighten the mounting nut to 22 N´m (200 in. lbs.).
(5) Plug in the wire harness connector to the a/c
high pressure switch.
(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)
LIQUID LINE
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(3) Disconnect the liquid line refrigerant line cou-
plers at the condenser outlet and the evaporator
inlet. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE - A/C
LINE COUPLERS) Install plugs in, or tape over all
of the opened refrigerant line fittings.
(4) Disengage any clips that secure the liquid line
to the inner fender shield and the dash panel (Fig.
10).
(5) Remove the liquid line from the vehicle.
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)(Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
(1) Install the liquid line into any clips on the
inner fender shield and the dash panel.
(2) Remove the tape or plugs from the refrigerant
line fittings on the liquid line, the condenser outlet,
and the evaporator inlet. Connect the liquid line to
the condenser and the evaporator. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - A/C LINE COUPLERS)
(3) Connect the battery negative cable.
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
24 - 52 PLUMBINGBR/BE
SUCTION AND DISCHARGE LINE (Continued)