warning JEEP LIBERTY 2002 KJ / 1.G Workshop Manual
[x] Cancel search | Manufacturer: JEEP, Model Year: 2002, Model line: LIBERTY, Model: JEEP LIBERTY 2002 KJ / 1.GPages: 1803, PDF Size: 62.3 MB
Page 1696 of 1803
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)
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.
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 - REFRIGERANT OIL LEVEL) Use only
refrigerant oil of the type recommended for the
compressor in the vehicle. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/REFRIGERANT OIL -
DESCRIPTION)(1) Install the compressor to the mounting bracket.
Tighten the three mounting bolts to 27 N´m (20 ft.
lbs.), (2.4L gasoline and 2.5L diesel engines only).
(2) On the 3.7L gasoline engine install and tighten
the bolts in the following sequence (Fig. 5):
²The number one bolt (rear) is hand tightened
first then tightened to 55 N´m (41 ft. lbs.)
²The number three bolt is then hand tightened
and torqued to 40 N´m ( 30 ft. lbs.)
²The number two bolt is also hand tightened and
torqued to 55 N´m ( 41 ft. lbs.)
(3) Remove the tape or plugs from all of the
opened refrigerant line fittings. Install the suction
and discharge line manifold to the compressor.
Tighten the fastener to 28 N´m (250 in. lbs.).(Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
SUCTION LINE - INSTALLATION) (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - INSTALLATION)
(4) Install the serpentine drive belt(Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
Fig. 3 A/C COMPRESSOR - 3.7L ENGINE
1 - COMPRESSOR BOLT #1
2 - COMPRESSOR BOLT #2
3 - COMPRESSOR BOLT #3
4 - A/C COMPRESSOR
5 - A/C COMPRESSOR CLUTCH AND PULLEY
6 - COMPRESSOR MOUNT
Fig. 4 A/C COMPRESSOR - 2.5L DIESEL ENGINE
1 - SUCTION LINE MOUNTING NUT
2- SUCTION LINE MOUNTING CLIP
3- SUCTION LINE
4- MOUNTING SCREW FOR SUCTION LINE
5- SUCTION LINE MOUNTING FLANG
6- MOUNTING SCREW FOR DISCHARGE LINE
7- DISCHARGE LINE MOUNTING FLANG
8- A/C PRESSURE SENSOR
9- A/C DISCHARGE LINE
10- A/C COMPRESSOR ASSEMBLY
11- A/C DISCHARGE LINE SERVICE PORT
24 - 44 PLUMBINGKJ
A/C COMPRESSOR (Continued)
Page 1697 of 1803
(5) Plug in the compressor clutch coil wire harness
connector.
(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)
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.
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. Thevolume 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) Disconnect the discharge line refrigerant line
fitting at the condenser inlet. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE - A/C LINE COUPLERS)
Install plugs in, or tape over all of the opened refrig-
erant line fittings.
(4) Disconnect the liquid line (Left-Hand Drive) or
liquid line jumper (Right-Hand Drive) refrigerant
line fitting at the condenser 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) Remove the radiator and the condenser from
the vehicle as a unit. Refer to Cooling for the proce-
dures.
(6) Remove the two nuts that secure the condenser
studs to the upper brackets of the radiator (Fig. 6).
(7) Slide the condenser down from the radiator far
enough for the condenser studs to clear the upper
radiator bracket holes, and for the lower condenser
bracket holes to clear the dowel pins on the bottom of
the radiator.
(8) Remove the condenser from the radiator.
Fig. 5 A/C COMPRESSOR - 3.7L ENGINE
1 - COMPRESSOR BOLT #1
2 - COMPRESSOR BOLT #2
3 - COMPRESSOR BOLT #3
4 - A/C COMPRESSOR
5 - A/C COMPRESSOR CLUTCH AND PULLEY
6 - COMPRESSOR MOUNT
KJPLUMBING 24 - 45
A/C COMPRESSOR (Continued)
Page 1698 of 1803
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 holes of the condenser lower brack-
ets over the dowel pins on the bottom of the radiator.
(2) Slide the condenser upwards until both of the
condenser studs are installed through the holes in
the radiator upper brackets. Tighten the mounting
nuts to 5.3 N´m (47 in. lbs.).
(3) Reinstall the radiator and condenser unit in
the vehicle(Refer to 7 - COOLING/ENGINE/RADIA-
TOR - INSTALLATION).
(4) Remove the tape or plugs from the refrigerant
line fittings on the condenser outlet and the liquid
line (Left-Hand Drive) or the liquid line jumper
(Right-Hand Drive). Install the liquid line or the liq-
uid line jumper to the condenser outlet. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - A/C LINE COUPLERS)
(5) Remove the tape or plugs from the refrigerant
line fittings on the condenser inlet and the dischargeline. Connect the discharge line to the condenser
inlet. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE - A/C
LINE COUPLERS)
(6) Connect the battery negative cable.
(7) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(8) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT OIL - DESCRIPTION)
A/C 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
high pressure cut-off switch.
(4) Disconnect the discharge line refrigerant line
fitting from the condenser inlet tube (Fig. 7). (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) Remove the nut that secures the suction line
block fitting to the accumulator outlet. Install plugs
in, or tape over all of the opened refrigerant line fit-
tings.
(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.
Fig. 6 CONDENSER REMOVE/INSTALL
1 - NUT
2 - RADIATOR
3 - GROMMET
4 - LOWER CROSSMEMBER
5 - CONDENSER
6 - STUDS
24 - 46 PLUMBINGKJ
A/C CONDENSER (Continued)
Page 1699 of 1803
(7) 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 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 block fittings. Install the
suction line to the accumulator outlet and tighten the
mounting nut to 9 N´m (80 in. lbs.).(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 cut-off 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 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.(Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE - REFRIGERANT RECOVERY)
(3) Disconnect the liquid line refrigerant line cou-
plers at the evaporator inlet and the condenser outlet
(Fig. 8). (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
A/C LINE COUPLERS) Install plugs in, or tape over
all of the opened refrigerant line fittings.
(4) 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) Remove the tape or plugs from the refrigerant
line fittings on the liquid line, the evaporator inlet
Fig. 7 SUCTION AND DISCHARGE LINE REMOVAL
1 - Condensor connection
2- Discharge line to condensor mounting nut
3- Discharge line
4- Discharge line charging port
5- Suction line
6- Evaporator mounting ports
7- Accumulator
8- High pressure cut off switch
9- AC compressor
10- AC condensor
KJPLUMBING 24 - 47
A/C DISCHARGE LINE (Continued)
Page 1700 of 1803
and the condenser outlet. Connect the liquid line to
the evaporator inlet and condenser outlet refrigerant
line couplers. (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - STANDARD PROCE-
DURE - A/C LINE COUPLERS)
(2) Connect the battery negative cable.
(3) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(4) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
A/C SUCTION 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 negative battery
cable.
(2) Recover the refrigerant. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE - REFRIGERANT RECOVERY)
(3) Unplug the wire harness connector from the a/c
high pressure switch (Fig. 9).
(4) Disconnect the discharge line refrigerant fitting
from the condenser inlet tube. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE - A/C LINE COUPLERS)
Install plugs in, or tape over all of the opened refrig-
erant line fittings.
(5)
Remove the nut that secures the suction line
block fitting to the accumulator outlet. Install plugs in,
or tape over all of the opened refrigerant line fittings.
(6)Remove the fastener that secures the suction and
discharge line manifold to the compressor. Install plugs
in, or tape over all of the opened refrigerant line fit-
tings.
Fig. 8 LIQUID LINE REMOVE/INSTALL
1 - AC Condensor
2- AC condensor connector ports
3- Liquid line to condensor connector
4- Mounting nut
5- Liquid line
6- Liquid line mounting clips (2)
7- Mounting nut
8- Liquid line to evaporator connection
9- Evaporator connection
Fig. 9 SUCTION AND DISCHARGE LINE REMOVAL
1 - Condensor connection
2- Discharge line to condensor mounting nut
3- Discharge line
4- Discharge line charging port
5- Suction line
6- Evaporator mounting ports
7- Accumulator
8- High pressure cut off switch
9- AC compressor
10- AC condensor
24 - 48 PLUMBINGKJ
A/C LIQUID LINE (Continued)
Page 1701 of 1803
(7) Remove the suction and discharge line assem-
bly from the vehicle.
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT IF 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 block fittings. Install the
suction line to the accumulator outlet and tighten the
mounting nut to 9 N´m (80 in. lbs.).
(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 on 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)
(8) Check the affected areas of the system for
leaks.
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 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: 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. 10).
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)
KJPLUMBING 24 - 49
A/C SUCTION LINE (Continued)
Page 1703 of 1803
replaced. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/LIQUID LINE - REMOVAL)
ACCUMULATOR
DESCRIPTION
The accumulator is mounted in the engine com-
partment between the evaporator coil 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 (Fig. 12).
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
low pressure cycling clutch switch.
(4) Loosen the screw that secures the accumulator
retaining band to the support bracket on the dash
panel (Fig. 13).
(5) Disconnect the suction line from the accumula-
tor outlet tube refrigerant line fitting. (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) Disconnect the accumulator inlet tube refriger-
ant line fitting from the evaporator outlet tube.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - A/C LINE
COUPLERS) Install plugs in, or tape over all of the
opened refrigerant line fittings.
(7) Pull the accumulator and retaining band unit
forward until the screw in the band is clear of the
slotted hole in the support bracket on the dash panel.
(8) Remove the accumulator 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 accumulator and retaining band as
a unit by sliding the screw in the band into the slot-
ted hole in the support bracket on the dash panel.
(2) Remove the tape or plugs from the refrigerant
line fittings on the accumulator inlet tube and the
Fig. 12 ACCUMULATOR - TYPICAL
1 - A/C LOW PRESSURE SWITCH
2 - PRESSURE SWITCH FITTING
3 - OUTLET TO COMPRESSOR
4 - ANTI-SIPHON HOLE
5 - DESICCANT BAG
6 - OIL RETURN ORIFICE FILTER
7 - VAPOR RETURN TUBE
8 - ACCUMULATOR DOME
9 - O-RING SEAL
10 - INLET FROM EVAPORATOR
KJPLUMBING 24 - 51
A/C ORIFICE TUBE (Continued)
Page 1704 of 1803
evaporator outlet tube. Connect the accumulator inlet
tube refrigerant line coupler to the evaporator outlet
tube. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE - A/C
LINE COUPLERS)
(3) Tighten the accumulator retaining band screw
to 5 N´m (45 in. lbs.).
(4) Remove the tape or plugs from the refrigerant
line fittings on the suction line and the accumulator
outlet tube. Connect the suction line to the accumu-
lator outlet tube refrigerant line coupler. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - A/C LINE COUPLERS)
(5) Plug the wire harness connector into the low
pressure cycling clutch 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)NOTE: If the accumulator 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)
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 and uses warm engine
coolant as its heat source.
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.
Fig. 13 A/C LOW PRESSURE SWITCH
1 - WIRING HARNESS CONNECTOR
2 - A/C LOW PRESSURE SWITCH
3 - A/C LINE TO EVAPORATOR
4 - ACCUMULATOR MOUNTING BRACKET
5 - ACCUMULATOR
6 - A/C LOW PRESSURE LINE
24 - 52 PLUMBINGKJ
ACCUMULATOR (Continued)
Page 1705 of 1803
WARNING: IF THE VEHICLE IS EQUIPPED WITH AIR
CONDITIONING, REVIEW THE WARNINGS AND
CAUTIONS IN THE FRONT OF THIS SECTION
BEFORE PERFORMING THE FOLLOWING OPERA-
TION. (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
(1) Remove the HVAC housing. (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).
(2) Remove the two heater core retaining screws (if
equipped). (Fig. 14).
(3) Gently push back on two of the heater core
retaining tabs and pull up on heater core to remove.
INSTALLATION
WARNING: IF THE VEHICLE IS EQUIPPED WITH AIR
CONDITIONING, REVIEW THE WARNINGS AND
CAUTIONS IN THE FRONT OF THIS SECTION
BEFORE PERFORMING THE FOLLOWING OPERA-
TION. (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 heater core into the top of the
HVAC housing.
(2) Push on top of heater core until all for tabs are
locked into place.
(3) Install the two heater core retainer screws.
(4) Install the HVAC housing. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION)
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
Fig. 14 HEATER CORE REMOVAL/INSTALLATION
1 - HEATER CORE
2- MOUNTING SCREW HOLE
3- INLET AND OUTLET TUBES
4- VACUUM HARNESS
5- ACTUATOR SCREWS (3)
6- ELECTRIC BLEND DOOR ACTUATOR
7- MOUNTING SCREW HOLE
8- HEATER CORE RETAINER TABS (4)
KJPLUMBING 24 - 53
HEATER CORE (Continued)
Page 1728 of 1803
²Priority4ÐTwotrip failure or matured fault
for fuel system (rich/lean) and misfire or one trip cat-
alyst damaging misfire.
Non-emissions related failures have no priority.
One trip failures of two trip faults have low priority.
Two trip failures or matured faults have higher pri-
ority. One and two trip failures of fuel system and
misfire monitor take precedence over non-fuel system
and non-misfire failures.
DTC Self Erasure
With one trip components or systems, the MIL is
illuminated upon test failure and DTCs are stored.
Two trip monitors are components requiring failure
in two consecutive trips for MIL illumination. Upon
failure of the first test, the Task Manager enters a
maturing code. If the component fails the test for a
second time the code matures and a DTC is set.
After three good trips the MIL is extinguished and
the Task Manager automatically switches the trip
counter to a warm-up cycle counter. DTCs are auto-
matically erased following 40 warm-up cycles if the
component does not fail again.
For misfire and fuel system monitors, the compo-
nent must pass the test under a Similar Conditions
Window in order to record a good trip. A Similar Con-
ditions Window is when engine RPM is within 375
RPM and load is within 10% of when the fault
occurred.
NOTE: It is important to understand that a compo-
nent does not have to fail under a similar window of
operation to mature. It must pass the test under a
Similar Conditions Window when it failed to record
a Good Trip for DTC erasure for misfire and fuel
system monitors.
DTCs can be erased anytime with a DRB III. Eras-
ing the DTC with the DRB III erases all OBD II
information. The DRB III automatically displays a
warning that erasing the DTC will also erase all
OBD II monitor data. This includes all counter infor-
mation for warm-up cycles, trips and Freeze Frame.
Trip Indicator
TheTripis essential for running monitors and
extinguishing the MIL. In OBD II terms, a trip is a
set of vehicle operating conditions that must be met
for a specific monitor to run. All trips begin with a
key cycle.
Good Trip
The Good Trip counters are as follows:
²Specific Good Trip
²Fuel System Good Trip
²Misfire Good Trip
²Alternate Good Trip (appears as a Global Good
Trip on DRB III)²Comprehensive Components
²Major Monitor
²Warm-Up Cycles
Specific Good Trip
The term Good Trip has different meanings
depending on the circumstances:
²If the MIL is OFF, a trip is defined as when the
Oxygen Sensor Monitor and the Catalyst Monitor
have been completed in the same drive cycle.
²If the MIL is ON and a DTC was set by the Fuel
Monitor or Misfire Monitor (both continuous moni-
tors), the vehicle must be operated in the Similar
Condition Window for a specified amount of time.
²If the MIL is ON and a DTC was set by a Task
Manager commanded once-per-trip monitor (such as
the Oxygen Sensor Monitor, Catalyst Monitor, Purge
Flow Monitor, Leak Detection Pump Monitor, EGR
Monitor or Oxygen Sensor Heater Monitor), a good
trip is when the monitor is passed on the next start-
up.
²If the MIL is ON and any other emissions DTC
was set (not an OBD II monitor), a good trip occurs
when the Oxygen Sensor Monitor and Catalyst Mon-
itor have been completed, or two minutes of engine
run time if the Oxygen Sensor Monitor and Catalyst
Monitor have been stopped from running.
Fuel System Good Trip
To count a good trip (three required) and turn off
the MIL, the following conditions must occur:
²Engine in closed loop
²Operating in Similar Conditions Window
²Short Term multiplied by Long Term less than
threshold
²Less than threshold for a predetermined time
If all of the previous criteria are met, the PCM will
count a good trip (three required) and turn off the
MIL.
Misfire Good Trip
If the following conditions are met the PCM will
count one good trip (three required) in order to turn
off the MIL:
²Operating in Similar Condition Window
²1000 engine revolutions with no misfire
Warm-Up Cycles
Once the MIL has been extinguished by the Good
Trip Counter, the PCM automatically switches to a
Warm-Up Cycle Counter that can be viewed on the
DRB III. Warm-Up Cycles are used to erase DTCs
and Freeze Frames. Forty Warm-Up cycles must
occur in order for the PCM to self-erase a DTC and
Freeze Frame. A Warm-Up Cycle is defined as fol-
lows:
²Engine coolant temperature must start below
and rise above 160É F
²Engine coolant temperature must rise by 40É F
²No further faults occur
25 - 22 EMISSIONS CONTROLKJ
EMISSIONS CONTROL (Continued)