air conditioning DODGE RAM 2003 Service Manual Online

NOTE: Removal of the front bumper on the V-10 is
required, failure to do so could result in damage to
the condenser assembly and the bumper.
(3) Remove the front bumper assembly from the
vehicle(Refer to 13 - FRAME & BUMPERS/
BUMPERS/FRONT BUMPER - REMOVAL).
(4) Remove hood latch bolts and set hood latch
assembly aside(Refer to 23 - BODY/HOOD/LATCH -
REMOVAL).
(5) Remove a/c lines from condenser(Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - REMOVAL) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
SUCTION LINE - REMOVAL). Install plugs or tape
over all open connections (Fig. 7).
(6) Remove two bolts from top of condenser shroud
assembly (Fig. 8).
(7) Lift condenser and shift assembly to passenger
side of vehicle and remove from vehicle.
(8) With condenser and shroud on a clean flat
work area remove condenser retainer screws and sep-
arate condenser from shroud.
INSTALLATION
INSTALLATION - 3.7, 4.7 and 5.7L ENGINES
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
(1) Install the condenser lower dowel pins to the
bottom of the support rail.
(2) Position the condenser until both of the con-
denser studs are installed through the holes in the
upper support rail. Tighten the mounting nuts to 5.3
N´m (47 in. lbs.).
(3) Remove the tape or plugs from the refrigerant
line fittings on the condenser outlet and the liquid
line. Install the liquid line or the liquid line jumper
to the condenser outlet. (Refer to 24 - HEATING &
Fig. 7 CONDENSER LINES
1 - Discharge line to condenser
2 - Mounting nut
3 - Mounting nut
4 - Liquid line
5 - A/C condenser shroud
6 - A/C condenser
Fig. 8 A/C CONDENSER
1 -A/C shroud mounting bolt
2 - Hood latch bolt
3 - Hood latch assembly
4 - Hood latch bolt
5 - A/C shroud mounting bolt
6 - A/C discharge line
7 - A/C liquid line
8 - Condenser to shroud mounting bolts (5)
9 - A/C condenser
10 - Condenser to shroud mounting bolts (5)
DRPLUMBING 24 - 41
A/C CONDENSER (Continued)

AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE - A/C LINE COUPLERS)
(4) Remove the tape or plugs from the refrigerant
line fittings on the condenser inlet and the discharge
line. Connect the discharge line to the condenser
inlet. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE - A/C
LINE COUPLERS)
(5) Connect the battery negative cable.
(6) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT OIL - DESCRIPTION)
INSTALLATION - 5.9L DIESEL ENGINE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)(Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
(1) On diesel engine models:
(a) Install the driver side condenser mounting
brackets over the two studs on the charge air
cooler.
(b) Install the two screws that secure the brack-
ets on the passenger side end of the condenser to
the charge air cooler. Tighten the mounting screws
to 10.5 N´m (95 in. lbs.).
(c) Install the two nuts that secure the driver
side end of the condenser to the studs on the
charge air cooler. Tighten the mounting nuts to
10.5 N´m (95 in. lbs.).
(2) Remove the plugs or tape from the refrigerant
line fittings on the liquid line and the condenser out-
let. Connect the liquid line to the condenser outlet.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - A/C LINE
COUPLERS)(3) Install a new gasket and the discharge line
block fitting over the stud on the condenser inlet.
Tighten the mounting nut to 20 N´m (180 in. lbs.).
(4) Check that all of the condenser and radiator
air seals are in their proper locations.
(5) Connect the battery negative cable.
(6) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT OIL - DESCRIPTION)
INSTALLATION - 8.0L Engine
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION(Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) AND (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) If the condenser was removed from the shroud,
install it and tighten the mounting screws.
(2) Install the condenser and shroud in the vehicle.
Make sure the lower mounting flanges are positioned
correctly before installing the two mounting screws
to the radiator brace. Tighten the screws to spec.
(3) Remove and plugs or tape installed over the
condenser connections and the a/c lines.
(4) Install the lines to the condenser(Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - INSTALLATION) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
SUCTION LINE - INSTALLATION).
(5) Install the hood latch assembly(Refer to 23 -
BODY/HOOD/LATCH - INSTALLATION).
(6) Install the front bumper assembly(Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT BUMPER
- INSTALLATION).
(7) Evacuate the a/c system(Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
24 - 42 PLUMBINGDR
A/C CONDENSER (Continued)

NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle(Re-
fer to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/REFRIGERANT OIL - DESCRIPTION).
(8) Charge the a/c system(Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE).
(9) Install the battery negative cable.
A/C CONDENSER FAN
REMOVAL - CONDENSER FAN (GAS ENGINE
ONLY - 3.7, 4.7 & 5.7L)
(1) Remove and isolate negative battery cable.
(2) Remove condenser assembly(Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
CONDENSER - REMOVAL).
(3) Place condenser assembly on a flat work area
and remove screws holding fan assembly to con-
denser.
(4) Separate fan assembly from condenser noting
location of all seals for reinstallation.
INSTALLATION - CONDENSER FAN (GAS
ENGINE ONLY - 3.7, 4.7 & 5.7L)
(1) Position fan assembly on to the condenser.
(2) Check all fan shroud seals and replace as
required then install retainer screws to hold fan
assembly to condenser.
(3) Install condenser and fan assembly to vehi-
cle(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - INSTALLATION).
(4) Install battery negative cable.
A/C DISCHARGE LINE
REMOVAL
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(3) Unplug the wire harness connector from the
high pressure transducer.
(4) Disconnect the discharge line refrigerant line
fitting from the condenser inlet tube (Fig. 9). (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE - A/C LINE COU-
PLERS) Install plugs in, or tape over all of the
opened refrigerant line fittings.
(5) Disconnect the connection that secures the suc-
tion line fitting to the accumulator outlet. Install
plugs in, or tape over all of the opened refrigerant
line fittings.
(6) Remove the screw that secures the suction and
discharge line manifold to the compressor. Install
plugs in, or tape over all of the opened refrigerant
line fittings.
(7) Remove the suction and discharge line assem-
bly from the vehicle.REMOVAL - 5.9L DIESEL ENGINE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the battery negative
cable.
Fig. 9 A/C Discharge Line
1 - Discharge Line Retainer Nut
2 - Front Upper Cross Brace
3 - Condensor Module Port
4 - Suction and Discharge Line Retainer Screw
5 - Suction Line
6 - A/C Compressor
7 - High Pressure Transducer Connector
8 - Discharge Line
DRPLUMBING 24 - 43
A/C CONDENSER (Continued)

(2) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(3) Unplug the wire harness connector from the a/c
high pressure switch.
(4) Disconnect the suction line refrigerant line cou-
pler at the accumulator. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE - A/C LINE COUPLER) Install plugs
in, or tape over all of the opened refrigerant line fit-
tings.
(5) Remove the nut that secures the block fitting
to the stud on the condenser inlet and disconnect the
discharge line from the condenser. Install plugs in, or
tape over all of the opened refrigerant line fittings.
(6) Remove the bolt that secures the refrigerant
line manifold to the compressor (Fig. 10). Install
plugs in, or tape over all of the opened refrigerant
line fittings.
(7) Remove the suction and discharge line assem-
bly from the vehicle.
INSTALLATION
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
(1) Remove the tape or plugs from the suction and
discharge line manifold and the compressor. Install
the suction and discharge line manifold to the com-
pressor. Tighten the fastener to 28 N´m (250 in. lbs.).
(2) Remove the tape or plugs from the suction line
and the accumulator outlet fittings. Install the suc-
tion line to the accumulator outlet and install fas-
tener.
(3) Remove the tape or plugs from the refrigerant
line fittings on the discharge line and the condenser
inlet tube. Connect the discharge line refrigerant line
coupler to the condenser inlet tube. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - A/C LINE COUPLERS)
(4) Plug in the wire harness connector to the high
pressure transducer switch.
(5) Connect the battery negative cable.
(6) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
INSTALLATION - 5.9L DIESEL ENGINE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)(Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
(1) Remove the tape or plugs from all of the refrig-
erant line fittings. Connect the suction line refriger-
ant line coupler to the accumulator. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - A/C LINE COUPLERS)
(2) Install a new gasket and the discharge line
block fitting over the stud on the condenser inlet.
Tighten the mounting nut to 20 N´m (180 in. lbs.).
(3) Install the refrigerant line manifold to the com-
pressor. Tighten the mounting bolt to 22 N´m (200 in.
lbs.).
(4) Plug in the wire harness connector to the a/c
high pressure switch.
(5) Connect the battery negative cable.
(6) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
Fig. 10 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 - 44 PLUMBINGDR
A/C DISCHARGE LINE (Continued)

STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
LIQUID LINE
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the battery negative
cable.
NOTE: Removal of the second battery and battery
tray is required on the diesel equipped vehicles.
(2) Remove rightside battery(Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/BATTERY - REMOV-
AL).
(3) Remove rightside battery tray(Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/TRAY - REMOV-
AL).
(4) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(5) Disconnect the liquid line refrigerant line cou-
plers at the condenser outlet the mid point connec-
tion and the evaporator inlet. (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.
(6) Disengage any clips that secure the liquid line
to the inner fender shield or cross brace. (Fig. 11).
(7) Remove the both sections of the liquid line
from the vehicle.
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)(Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
(1) Install both sections of the liquid line into any
clips on the inner fender shield and the dash panel.
(2) Remove the tape or plugs from the refrigerant
line fittings on the liquid line, the condenser outlet,
and the evaporator inlet. Connect the liquid line
pieces together and to the condenser and the evapo-
rator. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE - A/C
LINE COUPLERS)
NOTE: Installation of the second battery and battery
tray is required on the diesel equipped vehicles.
(3) Install the rightside battery tray(Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/TRAY - INSTAL-
LATION).
(4) Install the rightside battery(Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/BATTERY - INSTAL-
LATION).
(5) Connect the battery positive cables.
(6) Connect the battery negative cables.
(7) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
Fig. 11 A/C Liquid Line - Gas Engine shown
1 - A/C Line Retainer Clip
2 - A/C Line Retention Clip
3 - A/C Line Retainer Clip
4 - Liquid Line to Evaporator
5 - A/C Line Retention Clip
6 - Evaporator Ports
7 - A/C Condensor Modular
8 - A/C Jumper Line Retainer Nut
9 - A/C Line Retainer Clip
10 - A/C Liquid Jumper Line
DRPLUMBING 24 - 45
A/C DISCHARGE LINE (Continued)

STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(8) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
SUCTION LINE
REMOVAL
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(3) Unplug the wire harness connector from the a/c
high pressure transducer.
(4) Disconnect the suction line refrigerant line cou-
pler at the accumulator. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE - A/C LINE COUPLER) Install plugs
in, or tape over all of the opened refrigerant line fit-
tings.
(5) Remove the nut that secures the condenser
inlet and disconnect the discharge line from the con-
denser. Install plugs in, or tape over all of the opened
refrigerant line fittings.
(6) Remove the suction and discharge line assem-
bly from the vehicle.
REMOVAL - 5.9L DIESEL ENGINE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(3) Unplug the wire harness connector from the a/c
high pressure switch.
(4) Disconnect the suction line refrigerant line cou-
pler at the accumulator. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE - A/C LINE COUPLER) Install plugs
in, or tape over all of the opened refrigerant line fit-
tings.
(5) Remove the nut that secures the block fitting
to the stud on the condenser inlet and disconnect the
discharge line from the condenser. Install plugs in, or
tape over all of the opened refrigerant line fittings.
(6) Remove the bolt that secures the refrigerant
line manifold to the compressor (Fig. 12). Install
plugs in, or tape over all of the opened refrigerant
line fittings.
(7) Remove the suction and discharge line assem-
bly from the vehicle.
INSTALLATION
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)(Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
Fig. 12 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 - 46 PLUMBINGDR
LIQUID LINE (Continued)

(1) Remove the tape or plugs from all of the refrig-
erant line fittings. Connect the suction refrigerant
line coupler to the accumulator. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE - A/C LINE COUPLERS)
(2) Install a new gasket and the discharge line
block fitting over the stud on the condenser inlet.
Tighten the mounting nut to 20 N´m (180 in. lbs.).
(3) Install the refrigerant line manifold to the com-
pressor. Tighten the mounting bolt to 22 N´m (200 in.
lbs.).
(4) Plug in the wire harness connector to the A/C
high pressure transducer.
(5) Connect the battery negative cable.
(6) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)(Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
(1) Remove the tape or plugs from all of the refrig-
erant line fittings. Connect the suction line refriger-
ant line coupler to the accumulator. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - A/C LINE COUPLERS)
(2) Install a new gasket and the discharge line
block fitting over the stud on the condenser inlet.
Tighten the mounting nut to 20 N´m (180 in. lbs.).
(3) Install the refrigerant line manifold to the com-
pressor. Tighten the mounting bolt to 22 N´m (200 in.
lbs.).
(4) Plug in the wire harness connector to the a/c
high pressure switch.
(5) Connect the battery negative cable.
(6) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
A/C EVAPORATOR
DESCRIPTION
The A/C evaporator is located in the HVAC hous-
ing, under the instrument panel. The evaporator coil
is positioned in the HVAC housing so that all air that
enters the housing must pass over the fins of the
evaporator before it is distributed through the sys-
tem ducts and outlets. However, air passing over the
evaporator coil fins will only be conditioned when the
compressor is engaged and circulating refrigerant
through the evaporator coil tubes.
OPERATION
Refrigerant enters the evaporator from the fixed
orifice tube as a low-temperature, low-pressure liq-
uid. As air flows over the fins of the evaporator, the
humidity in the air condenses on the fins, and the
heat from the air is absorbed by the refrigerant. Heat
absorption causes the refrigerant to boil and vapor-
ize. The refrigerant becomes a low-pressure gas when
it leaves the evaporator.
The evaporator coil cannot be repaired and, if
faulty or damaged, it must be replaced.
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
(1) Remove the HVAC housing from the vehicle,
and disassemble the housing halves. (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL) (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - DISASSEMBLY)
(2) Lift the A/C evaporator out of the HVAC hous-
ing (Fig. 13).
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)(Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
DRPLUMBING 24 - 47
SUCTION LINE (Continued)

(1) Insert the evaporator coil into the bottom of the
HVAC housing. Make sure that the evaporator drain
is clean and unrestricted and evaporator deflector
shield is also installed.
(2) Reassemble and reinstall the HVAC housing in
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HVAC HOUSING -
ASSEMBLY) (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/HVAC HOUSING -
INSTALLATION)
NOTE: If the evaporator is replaced, add 60 millili-
ters (2 fluid ounces) of refrigerant oil to the refrig-
erant system.
A/C ORIFICE TUBE
DESCRIPTION
The fixed orifice tube is installed in the liquid line
between the outlet of the condenser and the inlet of
the evaporator. The fixed orifice tube is only serviced
as an integral part of the liquid line.
OPERATION
The inlet end of the fixed orifice tube has a nylon
mesh filter screen, which filters the refrigerant and
helps to reduce the potential for blockage of the
metering orifice by refrigerant system contaminants
(Fig. 14). The outlet end of the tube has a nylonmesh diffuser screen. The O-rings on the plastic body
of the fixed orifice tube seal the tube to the inside of
the liquid line and prevents the refrigerant from
bypassing the fixed metering orifice.
The fixed 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 fixed orifice tube.
The fixed orifice tube cannot be repaired and, if
faulty or plugged, the liquid line assembly must be
replaced.
DIAGNOSIS AND TESTING - FIXED ORIFICE
TUBE
The fixed orifice tube can be checked for proper
operation using the following procedure. However,
the fixed orifice tube is only serviced as a part of the
liquid line unit. If the results of this test indicate
that the fixed orifice tube is obstructed or missing,
the entire liquid line unit must be replaced.
WARNING: THE LIQUID LINE BETWEEN THE CON-
DENSER OUTLET AND THE FIXED ORIFICE TUBE
CAN BECOME HOT ENOUGH TO BURN THE SKIN.
USE EXTREME CAUTION WHEN PERFORMING THE
FOLLOWING TEST.
(1) Confirm that the refrigerant system is properly
charged. (Refer to 24 - HEATING & AIR CONDI-
TIONING - DIAGNOSIS AND TESTING - A/C PER-
FORMANCE)
(2) Start the engine. Turn on the air conditioning
system and confirm that the compressor clutch is
engaged.
(3) Allow the air conditioning system to operate for
five minutes.
(4) Lightly and cautiously touch the liquid line
near the condenser outlet at the front of the engine
Fig. 13 Dual Zone HVAC Housing- (typical single
zone)
1 - Passenger Side Blend Door Lever (if equipped)
2 - Passenger Side Blend Door (if equipped)
3 - Fin Sensor Wire
4 - Lower Blower Motor Mounting Housing
5 - HVAC Evaporator
6 - Fin Sensor
7 - Driver Side Blend Door
8 - Driver Side Blend Door Lever
Fig. 14 FIXED ORIFICE TUBE - TYPICAL
1 - DIFFUSER SCREEN
2 - ªOº RINGS
3 - INLET FILTER SCREEN
4 - ORIFICE
24 - 48 PLUMBINGDR
A/C EVAPORATOR (Continued)

compartment. The liquid line should be hot to the
touch.
(5) Touch the liquid line near the evaporator inlet
at the rear of the engine compartment. The liquid
line should be cold to the touch.
(6) If there is a distinct temperature differential
between the two ends of the liquid line, the orifice
tube is in good condition. If there is little or no
detectable temperature differential between the two
ends of the liquid line, the orifice tube is obstructed
or missing and the liquid line must be replaced.
REMOVAL
The fixed orifice tube is located in the liquid line,
between the condenser and the evaporator coil. The
orifice has filter screens on the inlet and outlet ends
of the tube body. If the fixed orifice tube is faulty or
plugged, the liquid line assembly must be replace-
d(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/LIQUID LINE - REMOVAL).
INSTALLATION
The fixed orifice tube is located in the liquid line,
between the condenser and the evaporator coil. The
orifice has filter screens on the inlet and outlet ends
of the tube body. If the fixed orifice tube is faulty or
plugged, the liquid line assembly must be replace-
d(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/LIQUID LINE - INSTALLATION).
ACCUMULATOR
DESCRIPTION
The accumulator is mounted in the engine com-
partment between the A/C evaporator outlet tube and
the compressor inlet.
OPERATION
Refrigerant enters the accumulator canister as a
low pressure vapor through the inlet tube. Any liq-
uid, oil-laden refrigerant falls to the bottom of the
canister, which acts as a separator. A desiccant bag is
mounted inside the accumulator canister to absorb
any moisture which may have entered and become
trapped within the refrigerant system.
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(3) Loosen the fasteners that secure the accumula-
tor and support bracket to the dash panel (Fig. 15).
(4) Disconnect the suction line refrigerant line fit-
ting from the accumulator outlet. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - A/C LINE COUPLERS)
Install plugs in, or tape over all of the opened refrig-
erant line fittings.
(5) Disconnect the accumulator inlet refrigerant
line fitting from the evaporator outlet. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE) Install plugs in, or tape
over all of the opened refrigerant line fittings.
(6) Remove the accumulator assembly from the
engine compartment.
Fig. 15 A/C Accumulator
1 - Inner Fender
2 - Line from Accumulator to Evaporator
3 - A/C Line Rentention Clip
4 - Evaporator Ports
5 - Accumulator Mounting Screws
6 - Accumulator
7 - Suction Line
8 - A/C Charging Port
9 - A/C Line Rentention Clip
DRPLUMBING 24 - 49
A/C ORIFICE TUBE (Continued)

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 accumulator to the bulkhead but do
not tighten yet.
(2) Remove the tape or plugs from the refrigerant
line fittings on the accumulator inlet and the evapo-
rator outlet. Connect the accumulator inlet refriger-
ant line coupler to the evaporator outlet. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - A/C LINE COUPLERS)
(3) Remove the tape or plugs from the refrigerant
line fittings on the suction line and the accumulator
outlet. Connect the suction line refrigerant line cou-
pler to the accumulator outlet. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - A/C LINE COUPLERS)
(4) Tighten the accumulator fasteners to 4.5 N´m
(40 in. lbs.).
(5) Connect the battery negative cable.
(6) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
NOTE: If the accumulator is replaced, add 60 milli-
liters (2 fluid ounces) of refrigerant oil to the refrig-
erant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
HEATER CORE
DESCRIPTION
The heater core is located in the HVAC housing,
under the instrument panel. It is a heat exchanger
made of rows of tubes and fins.
The heater core is not repairable and if damaged it
must be replaced.
OPERATION
Engine coolant is circulated through heater hoses
to the heater core at all times. As the coolant flowsthrough the heater core, heat removed from the
engine is transferred to the heater core fins and
tubes. Air directed through the heater core picks up
the heat from the heater core fins. The blend door
allows control of the heater output air temperature
by controlling how much of the air flowing through
the HVAC housing is directed through the heater
core. The blower motor speed controls the volume of
air flowing through the HVAC housing.
The heater core cannot be repaired and, if faulty or
damaged, it must be replaced.
REMOVAL
NOTE: Disassembly of the HVAC housing is not
required to remove heater core.
(1) Remove the HVAC housing from the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL)
(2) Remove the screws and retainers that secure
the heater core to the HVAC housing.
(3) Lift the heater core out of the heater-A/C hous-
ing.
(4) Inspect all seals and repair or replace as
required.
INSTALLATION
(1) Place the heater core into the HVAC housing.
(2) Snap the retainers for the heater core to the
housing. Install and tighten the screws that secure
the heater core to the HVAC housing (if equipped).
Tighten the screws to 2.2 N´m (20 in. lbs.).
(3) Reinstall the HVAC housing in the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - INSTALLA-
TION)
REFRIGERANT
DESCRIPTION
The refrigerant used in this air conditioning sys-
tem is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC),
R-134a refrigerant does not contain ozone-depleting
chlorine. R-134a refrigerant is a non-toxic, non-flam-
mable, clear, and colorless liquefied gas.
Even though R-134a does not contain chlorine, it
must be reclaimed and recycled just like CFC-type
refrigerants. This is because R-134a is a greenhouse
gas and can contribute to global warming.
OPERATION
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even a
24 - 50 PLUMBINGDR
ACCUMULATOR (Continued)