air conditioning JEEP GRAND CHEROKEE 2003 WJ / 2.G Manual PDF

ING & AIR CONDITIONING/PLUMBING/RE-
CEIVER / DRIER - INSTALLATION).
INSTALLATION - 2.7L TURBO DIESEL
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)
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. 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.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
(1) The liquid line is serviced as an integral part of
the receiver/drier bottle assembly(Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
CEIVER / DRIER - INSTALLATION).
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) Remove the retainer nut from the evaporator
connection (Fig. 8) or (Fig. 9).(4) Slide the suction line off the stud and liquid
line. Install plugs in, or tape over all the opened
refrigerant line fittings. Remove from clip.
(5) Remove the bolt that secures the suction line
fitting to compressor. Install plugs in, or tape over all
of the opened refrigerant line fittings.
(6) Remove the suction line assembly from the
vehicle.
Fig. 8 SUCTION LINE - I-6
1 - SUCTION LINE
2 - RECEIVER DRIER- LIQUID LINE
3 - H-BLOCK
Fig. 9 V-8 Suction Line
1 - SUCTION LINE TO H-BLOCK
2 - A/C COMPRESSOR
3 - SUCTION LINE TO COMPRESSOR
4 - RECEIVER DRIER ASSEMBLY
5 - H-BLOCK
WJPLUMBING 24 - 67
LIQUID LINE (Continued)

REMOVAL - 2.7L TURBO DIESEL
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 the negative battery cable.
(2) Recover the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY)
(3) Remove the refrigerant line retaining fastener
from the H-Valve Block (Fig. 10). Remove the line
and gasket from the H-Valve block and cap or tape
over both ends.
(4) Remove the refrigerant line support bracket
bolt from the cylinder head cap.
(5) Remove the refrigerant line retaining fastener
from the compressor inlet fitting. Remove the line
and cap the compressor outlet tube to prevent con-
tamination of the system.
(6) Unclip and remove the suction line 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)
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. 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.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
(1) Remove the tape or plugs from the suction line
block fitting and the manifold on the compressor.
Install the suction line block fitting to the manifold
on the compressor. Tighten the mounting bolt to 25.4
N´m (225 in. lbs.).
(2) Remove the tape or plugs from the refrigerant
line fittings on the evaporator outlet and the suction
line. Slide the suction line copnnection block over the
liquid line and evaporator stud. Tighten the retaining
nut to 28 N´m (250 in. lbs.).
(3) Connect the battery negative cable.
(4) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(5) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
Fig. 10 Suction-Discharge Lines- RHD (LHD-typical)
1 - SUCTION LINE
2 - H-BLOCK
3 - RECEIVER DRIER
4 - DISCHARGE LINE & SERVICE PORT
5 - A/C COMPRESSOR
6 - DISCHARGE LINE & CONDENSOR CONNECTION
24 - 68 PLUMBINGWJ
SUCTION LINE (Continued)

INSTALLATION - 2.7L TURBO DIESEL
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)
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. 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.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
(1) Carefully position the suction line in the vehi-
cle.
(2) Remove the cap or tape and install the suction
line on the compressor. Be certain the sealing o-ring
is well lubricated with PAG oil and free of tears.
Torque the retaining fastener to 22 N´m (200 in. lbs.).
(3) Position and install the refrigerant line support
bracket bolt on the cylinder head cap. Torque the bolt
to 20 N´m (177 in. lbs.).
(4) Remove the cap or tape and install the suction
line on the H-Valve Block. Be certain the sealing
O-ring is well lubricated with PAG oil and free of
tears. Torque the retaining fastener to 28 N´m (21 ft.
lbs.).
(5) Install the tie-straps retaining the wire har-
ness on the suction line.
(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)
(8) Connect the negative battery cable.
A/C EVAPORATOR
DESCRIPTION
The evaporator coil 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 orifice
tube as a low-temperature, low-pressure liquid. 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 absorp-
tion causes the refrigerant to boil and vaporize. The
refrigerant becomes a low-pressure gas before it
leaves the evaporator.
The evaporator coil cannot be repaired and, if
faulty or damaged, it must be replaced.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
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 and disassemble the HVAC housing.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL)
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - DISASSEMBLY)
(2) Lift the evaporator coil unit out of the lower
half of the HVAC housing (Fig. 11).
WJPLUMBING 24 - 69
SUCTION LINE (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)
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. 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.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
(1) Install the evaporator coil in the bottom half of
the HVAC housing. Be certain that the evaporator
foam insulator wrap is reinstalled.
(2) Reassemble the HVAC housing and install 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.
Fig. 11 HVAC HOUSING- CASE SEPARATED
1 - ELECTRICIAL CONNECTORS
2 - VACUUM ACTUATOR
3 - RECIRCULATION DOOR
4 - THERMAL EXPANSION VALVE
5 - BLOWER MOTOR RESISTOR/CONTROLLER
6 - BLOWER WHEEL
7 - EVAPORATOR AND TUBES
8 - FIN SENSOR PROBE9 - BLEND DOOR
10 - PIVOT SHAFT (MOTOR REMOVED)
11 - PANEL/OUTLET DOOR
12 - LOWER HOUSING
13 - VACUUM ACTUATORS
14 - UPPER HOUSING
15 - VACUUM HARNESS
24 - 70 PLUMBINGWJ
A/C EVAPORATOR (Continued)

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.
OPERATION
Engine coolant is circulated through heater hoses
to the heater core at all times. As the coolant flows
through 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 temperature
control door allows control of the heater output air
temperature by controlling how much of the air flow-
ing 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. Refer to Cooling for
more information on the engine cooling system, the
engine coolant and the heater hoses.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
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.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL)
(2) Remove the foam gasket surrounding the core
tubes.
NOTE: Notice the orientation of the irregularly
shaped gasket on the tubes. The gasket must be
placed correctly to ensure proper sealing against
the body during reinstallation.(3)
Remove the screws and retainers that secure the
heater core and tubes to the HVAC housing (Fig. 12).
(4) Remove the mode door actuator if necessary,
for clearance to remove the core.
(5) Lift the heater core straight up and out of the
HVAC housing (Fig. 13).
(6) When replacing individual tubes, loosen and
remove the round tube-to-core clamp, and pull tube
from core.
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)
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. 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.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
Fig. 12 HEATER CORE, TUBES, AND RETAINERS
1 - TUBE-TO-CORE CLAMPS
2 - GROUND STRAP
3 - HVAC HOUSING
4 - TUBE RETAINERS AND SCREWS
5 - HEATER CORE
WJPLUMBING 24 - 71

pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
(1) When installing individual tubes, insert tube
into core ensuring that tube O-ring is seated in core
and not pinched. Hold tube in seated position while
installing the round tube-to-core clamp (Fig. 14).
NOTE: The round tube-to-heater-core clamp should
be left loose enough to turn the tube in the core.
Position the core in the housing, and then tighten
the tube-to-heater-core clamp after orienting the
tubes to the molded HVAC housing.
(2) Lower the heater core into the HVAC housing.
(3) Install the mode door actuator, if removed from
housing for core removal.
(4) Position the retainers over the heater core
tubes. Install and tighten the screws that secure the
heater core and retainers to the HVAC housing.
Tighten the screws to 2.2 N´m (20 in. lbs.).NOTE: The grounding strap is to be attached to the
lower heater core tube retainer.
(5) Reinstall the HVAC housing to the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - INSTALLA-
TION)
RECEIVER / DRIER
DESCRIPTION
The receiver/drier is mounted in the engine com-
partment between the condenser and is part of the
liquid line assembly. The filter/drier cannot be
repaired, if the filter/drier is faulty, damaged, left
open to the atmosphere or contaminated the line
assembly must be replaced.
OPERATION
The filter-drier performs a filtering action to pre-
vent foreign material in the refrigerant from contam-
inating the expansion valve. A desiccant bag is
mounted inside the filter-drier canister to absorb any
Fig. 13 HEATER CORE AND TUBES - (Typical)
1 - ELECTRICAL CONNECTORS
2 - EXPANSION VALVE
3 - ELECTRIC ACTUATOR
4 - OUTLET TO DEFROSTER DUCTS
5 - ELECTRIC ACTUATOR
6 - FLOOR DUCT
7 - TO REAR PASSENGER FLOOR AIR DUCTS8 - FLOOR DUCT
9 - HEATER CORE AND TUBES
10 - HOUSING DRAIN
11 - BLOWER MOTOR RESISTOR/CONTROLLER
12 - BLOWER MOTOR
13 - GROUND STRAP
24 - 72 PLUMBINGWJ
HEATER CORE (Continued)

moisture which may have netered and become
trapped within the refrigerant system. In addition,
during periods of high demand air conditioner opera-
tion, the filter-drier acts as a reservoir to store sur-
plus refrigerant. Refrigerant enters the filter-drier as
a high-pressure, low-temperature liquid.
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) Recover the refrigerant from the refrigerant
system(Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE).
(2) Remove the battery and the battery tray(Refer
to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY -
REMOVAL) and (Refer to 8 - ELECTRICAL/BAT-
TERY SYSTEM/TRAY - REMOVAL).
(3) Remove the screw from the receiver/drier
bracket (Fig. 15) or (Fig. 16).
(4) Remove the retaining nut from the evaporator
connection and then slide the suction line off the
stud and liquid line.
(5) Remove the receiver/drier bracket from the
stud and disconnect the liquid line from the evapora-tor inlet. Install plugs in or tape over all of the evap-
orator connection openings and opened refrigerant
line fittings.
(6) Disconnect the liquid line from the condenser
outlet. Install plugs in, or tape over all of the opened
refrigerant line fittings.
(7) Remove liquid line assembly.
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)
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. 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.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to
Fig. 14 HEATER CORE, TUBES, AND O-RINGS
1 - HEATER CORE TUBES
2 - TUBE-TO-CORE CLAMPS
3 - SCREWS
4 - O-RINGS
5 - HEATER CORE
Fig. 15 COMPRESSOR AND A/C LINES - V8
1 - DISCHARGE LINE
2 - A/C COMPRESSOR
3 - SUCTION LINE
4 - A/C/ CONDENSOR
5 - DISCHARGE LINE TO CONDENSOR
6 - A/C PRESSURE TRANSDUCER SWITCH
7 - A/C/ SERVICE PORT
8 - RECEIVER DRIER
WJPLUMBING 24 - 73
RECEIVER / DRIER (Continued)

inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
(1) Remove the tape or plugs from the refrigerant
line fittings on the condenser outlet and the con-
denser end of the liquid line. Connect the liquid line
to the condenser outlet. Tighten the retaining nut to
20.16 N´m (180 in. lbs.).
(2) Remove the tape or plugs from the refrigerant
line fittings on the evaporator end of the liquid line
and the evaporator inlet. Place the receiver/drier
bracket on the stud and connect the liquid line to the
evaporator inlet.
(3) Remove the tape or plugs from the suction line
and evaporator outlet. Slide the suction line connec-
tion block on the liquid line on the evaporator con-
nection stud. Tighten the retaining nut to 20.16 N´m
( 180 in. lbs.).
(4) Insert a screw for the receiver/drier bracket
and hand turn three turns. Tighten the screw to
10.64 N´m (95 in. lbs.).(5) Install the battery tray and the battery(Refer
to 8 - ELECTRICAL/BATTERY SYSTEM/TRAY -
INSTALLATION) and (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(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 receiver/drier is replaced, add 120 mil-
liliters (4 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle. (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT OIL - DESCRIPTION)
Fig. 16 2.7L Diesel Compressor-RHD (LHD typical)
1 - SUCTION LINE MOUNTING SCREW
2 - SUCTION LINE TO H-BLOCK
3 - H-BLOCK
4 - RECEIVER DRIER
5 - LIQUID LINE SERVICE PORT6 - LIQUID LINE AND RECEIVER DRIER
7 - A/C COMPRESSOR
8 - A/C COMPRESSOR DRIVE BELT
9 - RADIATOR - CONDENSOR ASSEMBLY
24 - 74 PLUMBINGWJ
RECEIVER / DRIER (Continued)

REFRIGERANT
DESCRIPTION
The refrigerant used in this air conditioning sys-
tem is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC),
R-134a refrigerant does not contain ozone-depleting
chlorine. R-134a refrigerant is a non-toxic, non-flam-
mable, clear, and colorless liquefied gas.
Even though R-134a does not contain chlorine, it
must be reclaimed and recycled just like CFC-type
refrigerants. This is because R-134a is a greenhouse
gas and can contribute to global warming.
OPERATION
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even a
small amount of R-12 added to an R-134a refrigerant
system will cause compressor failure, refrigerant oil
sludge or poor air conditioning system performance.
In addition, the PolyAlkylene Glycol (PAG) synthetic
refrigerant oils used in an R-134a refrigerant system
are not compatible with the mineral-based refriger-
ant oils used in an R-12 refrigerant system.
R-134a refrigerant system service ports, service
tool couplers and refrigerant dispensing bottles have
all been designed with unique fittings to ensure that
an R-134a system is not accidentally contaminated
with the wrong refrigerant (R-12). There are also
labels posted in the engine compartment of the vehi-
cle and on the compressor identifying to service tech-
nicians that the air conditioning system is equipped
with R-134a.
REFRIGERANT OIL
DESCRIPTION
The refrigerant oil used in R-134a refrigerant sys-
tems is a synthetic-based, PolyAlkylene Glycol (PAG),
wax-free lubricant. Mineral-based R-12 refrigerant
oils are not compatible with PAG oils, and should
never be introduced to an R-134a refrigerant system.
There are different PAG oils available, and each
contains a different additive package. The 10PA17
compressor used in this vehicle is designed to use an
ND8 PAG refrigerant oil. Use only refrigerant oil of
this same type to service the refrigerant system.
OPERATION
After performing any refrigerant recovery or recy-
cling operation, always replenish the refrigerant sys-
tem with the same amount of the recommended
refrigerant oil as was removed. Too little refrigerant
oil can cause compressor damage, and too much can
reduce air conditioning system performance.PAG refrigerant oil is much more hygroscopic than
mineral oil, and will absorb any moisture it comes
into contact with, even moisture in the air. The PAG
oil container should always be kept tightly capped
until it is ready to be used. After use, recap the oil
container immediately to prevent moisture contami-
nation.
STANDARD PROCEDURE - REFRIGERANT OIL
LEVEL
When an air conditioning system is assembled at
the factory, all components except the compressor are
refrigerant oil free. After the refrigerant system has
been charged and operated, the refrigerant oil in the
compressor is dispersed throughout the refrigerant
system. The accumulator, evaporator, condenser, and
compressor will each retain a significant amount of
the needed refrigerant oil.
It is important to have the correct amount of oil in
the refrigerant system. This ensures proper lubrica-
tion of the compressor. Too little oil will result in
damage to the compressor. Too much oil will reduce
the cooling capacity of the air conditioning system.
It will not be necessary to check the oil level in the
compressor or to add oil, unless there has been an oil
loss. An oil loss may occur due to a rupture or leak
from a refrigerant line, a connector fitting, a compo-
nent, or a component seal. If a leak occurs, add 30
milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system after the repair has been made.
Refrigerant oil loss will be evident at the leak point
by the presence of a wet, shiny surface around the
leak.
Refrigerant oil must be added when a accumulator,
evaporator coil, or condenser are replaced. See the
Refrigerant Oil Capacities chart. When a compressor
is replaced, the refrigerant oil must be drained from
the old compressor and measured. Drain all of the
refrigerant oil from the new compressor, then fill the
new compressor with the same amount of refrigerant
oil that was drained out of the old compressor.
Refrigerant Oil Capacities
Component ml fl oz
A/C System 130 4.40
Receiver Drier 70 2.37
Condenser 10 0.34
Evaporator 50 1.69
Compressordrain and measure
the oil from the old
compressor - see
text.
WJPLUMBING 24 - 75

(M)Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded
(depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G)Generator lamp illuminated
Generic Scan
Tool P-CodeDRB Scan Tool Display Brief Description of DTC
P0545 A/C Clutch Relay Circuit Problem detected in air conditioning clutch relay control
circuit.
P0551 Power Steering Switch Failure Incorrect input state detected for the power steering
switch circuit. PL: High pressure seen at high speed.
P0562 Charging System Voltage Too Low Supply voltage sensed at ECM too low.
P0563 Charging System Voltage Too High Supply voltage sensed at ECM too high.
P0572 Brake Switch Input #1 Signal
Missing
P0573 Brake Switch Input #2 Signal
Missing
P0575 Cruise Control Switch Voltage Low
P0576 Cruise Control Switch Voltage High
P0577 Cruise Control Switch Voltage High
P0600 PCM Failure SPI Communications No communication detected between co-processors in the
control module.
P0601 (M) Internal Controller Failure Internal control module fault condition (check sum)
detected.
P0602 (M) ECM Fueling Calibration Error ECM Internal fault condition detected.
P0604 RAM Check Failure Transmission control module RAM self test fault detected.
-Aisin transmission
P0605 ROM Check Falure Transmission control module ROM self test fault detected
-Aisin transmission
P0606 (M) ECM Failure ECM Internal fault condition detected.
P0615 Starter Relay Control Circuit An open or shorted condition detected in the starter relay
control circuit.
P0622 (G) Generator Field Not Switching
ProperlyAn open or shorted condition detected in the generator
field control circuit.
P0645 A/C Clutch Relay Circuit An open or shorted condition detected in the A/C clutch
relay control circuit.
P0700 EATX Controller DTC Present This SBEC III or JTEC DTC indicates that the EATX or
Aisin controller has an active fault and has illuminated the
MIL via a CCD (EATX) or SCI (Aisin) message. The
specific fault must be acquired from the EATX via CCD or
from the Aisin via ISO-9141.
P0703 Brake Switch Stuck Pressed or
ReleasedIncorrect input state detected in the brake switch circuit.
(Changed from P1595)
P0703 Brake Switch Sense Circuit
P0711 (M) Trans Temp Sensor, No Temp Rise
After StartRelationship between the transmission temperature and
overdrive operation and/or TCC operation indicates a
failure of the Transmission Temperature Sensor. OBD II
Rationality. Was MIL code 37.
P0712 Trans Temp Sensor Voltage Too Low Transmission fluid temperature sensor input below
acceptable voltage. Was MIL code 37.
WJEMISSIONS CONTROL 25 - 9
EMISSIONS CONTROL (Continued)