2001 DODGE RAM warning

(3) Disengage the demister tubes from each end of
the main demister duct.
(4) Remove the defroster and demister duct unit
from the instrument panel.
REMOVAL - DEFROSTER AND DEMISTER
DUCT ADAPTER
(1) Roll the instrument panel assembly down, but
do not remove it from the vehicle. Refer to Instru-
ment Panel System for the procedures.
(2)
Using a trim stick or another suitable wide flat-
bladed tool, gently pry at the perimeter edges of the
defroster and demister duct adapter to release the snap
features from the top of the HVAC housing (Fig. 7).
(3) Remove the defroster and demister duct
adapter from the top of the HVAC housing.
INSTALLATION - DEFROSTER AND DEMISTER
DUCTS
(1) Place the defroster and demister duct unit in
position.
(2) Engage the demister tubes with each end of
the main demister duct.
(3) Install the screws that secure the defroster and
demister ducts to the instrument panel brackets.
Tighten the mounting screws to 2.2 N´m (20 in. lbs.).
(4) Install the instrument panel top cover on the
instrument panel. Refer to Instrument System for
the procedures.
INSTALLATION - DEFROSTER AND DEMISTER
DUCT ADAPTER
(1) Snap the defroster and demister duct adapter
from the top of the HVAC housing.
(2) Roll the instrument panel assembly up, and
fasten it properly to the vehicle. Refer to Instrument
Panel System for the procedures.
HVAC HOUSING
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO MIN-
UTES FOR THE AIRBAG SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD RESULT
IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POS-
SIBLE PERSONAL INJURY.
WARNING: IF THE VEHICLE IS EQUIPPED WITH AIR
CONDITIONING, REVIEW THE WARNINGS AND
CAUTIONS IN PLUMBING BEFORE PERFORMING
THE FOLLOWING OPERATION. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - WARNING)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - CAUTION)
The HVAC housing assembly must be removed
from the vehicle and disassembled for service access
of the heater core, a/c evaporator, and each of the
various mode control doors.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel from the vehicle.
Refer to Instrument Panel System for the procedures.
(3) If the vehicle is not equipped with air condi-
tioning, go to Step 6. If the vehicle is equipped with
air conditioning, recover the refrigerant from the sys-
tem. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(4) Disconnect the liquid line refrigerant line fit-
ting from the evaporator inlet tube. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - A/C LINE COUPLERS)
Install plugs in, or tape over all of the opened refrig-
erant line fittings.
Fig. 7 DEFROSTER AND DEMISTER DUCT
ADAPTER REMOVE/INSTALL
1 - DEFROSTER AND DEMISTER DUCT ADAPTER
2 - HVAC HOUSING
BR/BEDISTRIBUTION 24 - 35
DEFROSTER DUCTS (Continued)

BLEND DOOR
REMOVAL
(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 blend door pivot shaft out of the pivot
hole in the bottom of the HVAC housing (Fig. 11).
INSTALLATION
(1) Install the blend door pivot shaft in the bottom
of the HVAC housing.
(2) Assemble the HVAC housing. (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY)
(3) Install the HVAC housing in the vehicle. (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION/HVAC HOUSING - INSTALLATION)
MODE DOOR
REMOVAL - HEAT/DEFROST DOOR
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BATTERYNEGATIVE (GROUND) CABLE, THEN WAIT TWO MIN-
UTES FOR THE AIRBAG SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD RESULT
IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POS-
SIBLE PERSONAL INJURY.
WARNING: IF THE VEHICLE IS EQUIPPED WITH AIR
CONDITIONING, REVIEW THE WARNINGS AND
CAUTIONS IN PLUMBING BEFORE PERFORMING
THE FOLLOWING OPERATION. (Refer to 24 - HEAT-
ING & 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) Remove the heat/defrost door actuator from the
HVAC housing. (Refer to 24 - HEATING & AIR CON-
DITIONING/CONTROLS/MODE DOOR ACTUATOR
- REMOVAL)
(3) Remove the heat/defrost door from the HVAC
housing.
REMOVAL - PANEL/DEFROST DOOR
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO MIN-
UTES FOR THE AIRBAG SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD RESULT
IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POS-
SIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel assembly from
the vehicle. Refer to Instrument Panel System for the
procedures.
(3) Remove the panel/defrost door actuator from
the HVAC housing. (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/MODE DOOR
ACTUATOR - REMOVAL)
(4) Remove the defroster and demister duct
adapter from the HVAC housing. ***L***
Fig. 11 BLEND DOOR
1 - HEAT/DEFROST DOOR
2 - BLEND DOOR
24 - 38 DISTRIBUTIONBR/BE

(5) Lift the panel/defrost door out of the top open-
ing of the HVAC housing.
INSTALLATION - HEAT/DEFROST DOOR
(1) Install the heat/defrost door in the HVAC hous-
ing.
(2) Assemble the HVAC housing. (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY)
(3) Install the heat/defrost door actuator on the
HVAC housing. (Refer to 24 - HEATING & AIR CON-
DITIONING/CONTROLS/MODE DOOR ACTUATOR
- INSTALLATION)
(4) Install the HVAC housing in the vehicle. (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION/HVAC HOUSING - INSTALLATION)
INSTALLATION - PANEL/DEFROST DOOR
(1) Install the panel/defrost door through the top
opening of the HVAC housing.
(2) Install the defroster and demister duct adapter
on the HVAC housing. (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION/DEFROSTER
DUCTS - INSTALLATION)
(3) Install the panel/defrost door actuator on the
HVAC housing. (Refer to 24 - HEATING & AIR CON-
DITIONING/CONTROLS/MODE DOOR ACTUATOR
- REMOVAL)
(4) Install the instrument panel assembly in the
vehicle. Refer to Instrument Panel System for the
procedures.
(5) Connect the battery negative cable.
RECIRCULATION DOOR
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: IF THE VEHICLE IS EQUIPPED WITH AIR
CONDITIONING, REVIEW THE WARNINGS AND
CAUTIONS IN PLUMBING BEFORE PERFORMING
THE FOLLOWING OPERATION. (Refer to 24 - HEAT-
ING & 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) Unsnap the recirculation door vacuum actuator
link clip and disengage the link from the recircula-
tion door lever. (Refer to 24 - HEATING & AIR CON-
DITIONING/CONTROLS/RECIRCULATION DOOR
ACTUATOR - REMOVAL)
(3) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the retainer off of the
recirculation door pivot shaft.
(4) Remove the recirculation door through the out-
side air intake opening on the top of the HVAC hous-
ing.
INSTALLATION
(1) Install the recirculation door through the out-
side air intake opening on the top of the HVAC hous-
ing.
(2) Install the retainer on the recirculation door
pivot shaft.
(3) Engage the recirculation door vacuum actuator
link clip with the recirculation door lever. (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS/
RECIRCULATION DOOR ACTUATOR - INSTALLA-
TION)
(4) Install the HVAC housing in the vehicle. (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION/HVAC HOUSING - INSTALLATION)
BR/BEDISTRIBUTION 24 - 39
MODE DOOR (Continued)

PLUMBING
TABLE OF CONTENTS
page page
PLUMBING
DESCRIPTION...........................40
OPERATION.............................41
WARNING..............................41
CAUTION...............................41
DIAGNOSIS AND TESTING.................43
REFRIGERANT SYSTEM LEAKS...........43
STANDARD PROCEDURE..................43
A/C LINE COUPLERS....................43
REFRIGERANT SYSTEM SERVICE
EQUIPMENT...........................44
REFRIGERANT RECOVERY...............45
REFRIGERANT SYSTEM EVACUATE........45
REFRIGERANT SYSTEM CHARGE.........46
SPECIFICATIONS........................46
A/C COMPRESSOR
DESCRIPTION...........................46
OPERATION.............................46
DIAGNOSIS AND TESTING.................46
A/C COMPRESSOR.....................46
REMOVAL..............................47
INSTALLATION...........................47
A/C CONDENSER
DESCRIPTION...........................48
OPERATION.............................48
REMOVAL..............................49
INSTALLATION...........................49
SUCTION AND DISCHARGE LINE
REMOVAL..............................50
INSTALLATION...........................51
LIQUID LINE
REMOVAL..............................52INSTALLATION...........................52
A/C EVAPORATOR
DESCRIPTION...........................52
OPERATION.............................53
REMOVAL..............................53
INSTALLATION...........................53
A/C ORIFICE TUBE
DESCRIPTION...........................53
OPERATION.............................53
DIAGNOSIS AND TESTING.................54
FIXED ORIFICE TUBE...................54
REMOVAL..............................54
ACCUMULATOR
DESCRIPTION...........................54
OPERATION.............................54
REMOVAL..............................54
INSTALLATION...........................55
HEATER CORE
DESCRIPTION...........................55
OPERATION.............................55
REMOVAL..............................56
INSTALLATION...........................56
REFRIGERANT
DESCRIPTION...........................56
OPERATION.............................56
REFRIGERANT OIL
DESCRIPTION...........................56
OPERATION.............................56
STANDARD PROCEDURE..................57
REFRIGERANT OIL LEVEL................57
PLUMBING
DESCRIPTION - A/C LINE COUPLERS
Spring-lock type refrigerant line couplers are used
to connect many of the refrigerant lines and other
components to the refrigerant system. These couplers
require a special tool for disengaging the two coupler
halves.
DESCRIPTION
The refrigerant lines and hoses are used to carry
the refrigerant between the various air conditioning
system components. A barrier hose design with a
nylon tube, which is sandwiched between rubber lay-
ers, is used for the R-134a air conditioning system onthis vehicle. This nylon tube helps to further contain
the R-134a refrigerant, which has a smaller molecu-
lar structure than R-12 refrigerant. The ends of the
refrigerant hoses are made from lightweight alumi-
num or steel, and commonly use braze-less fittings.
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.
24 - 40 PLUMBINGBR/BE

OPERATION - A/C LINE COUPLERS
The spring-lock coupler is held together by a garter
spring inside a circular cage on the male half of the
fitting (Fig. 1). When the two coupler halves are con-
nected, the flared end of the female fitting slips
behind the garter spring inside the cage on the male
fitting. The garter spring and cage prevent the flared
end of the female fitting from pulling out of the cage.
Two O-rings on the male half of the fitting are
used to seal the connection. These O-rings are com-
patible with R-134a refrigerant and must be replaced
with O-rings made of the same material.
Secondary clips are installed over the two con-
nected coupler halves at the factory for added blowoff
protection. In addition, some models have a plastic
ring that is used at the factory as a visual indicator
to confirm that these couplers are connected. After
the coupler is connected, the plastic indicator ring is
no longer needed; however, it will remain on the
refrigerant line near the coupler cage.
OPERATION
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.The refrigerant lines and hoses are coupled with
other components of the HVAC system with peanut-
block style fittings. A stat-O seal type flat steel gas-
ket with a captured compressible O-ring, is used to
mate plumbing lines with A/C components to ensure
the integrity of the refrigerant system.
The refrigerant lines and hoses cannot be repaired
and, if faulty or damaged, they must be replaced.
WARNING:
THE AIR CONDITIONING SYSTEM CONTAINS
REFRIGERANT UNDER HIGH PRESSURE. SEVERE
PERSONAL INJURY MAY RESULT FROM IMPROPER
SERVICE PROCEDURES. REPAIRS SHOULD ONLY
BE PERFORMED BY QUALIFIED SERVICE PERSON-
NEL.
AVOID BREATHING THE REFRIGERANT AND
REFRIGERANT OIL VAPOR OR MIST. EXPOSURE
MAY IRRITATE THE EYES, NOSE, AND/OR THROAT.
WEAR EYE PROTECTION WHEN SERVICING THE
AIR CONDITIONING REFRIGERANT SYSTEM. SERI-
OUS EYE INJURY CAN RESULT FROM DIRECT
CONTACT WITH THE REFRIGERANT. IF EYE CON-
TACT OCCURS, SEEK MEDICAL ATTENTION IMME-
DIATELY.
DO NOT EXPOSE THE REFRIGERANT TO OPEN
FLAME. POISONOUS GAS IS CREATED WHEN
REFRIGERANT IS BURNED. AN ELECTRONIC LEAK
DETECTOR IS RECOMMENDED.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE THE WORK AREA BEFORE RESUMING
SERVICE. LARGE AMOUNTS OF REFRIGERANT
RELEASED IN A CLOSED WORK AREA WILL DIS-
PLACE THE OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF R-134a REFRIGER-
ANT AT AVERAGE TEMPERATURE AND ALTITUDE
IS EXTREMELY HIGH. AS A RESULT, ANYTHING
THAT COMES IN CONTACT WITH THE REFRIGER-
ANT WILL FREEZE. ALWAYS PROTECT THE SKIN
OR DELICATE OBJECTS FROM DIRECT CONTACT
WITH THE REFRIGERANT.
THE R-134a SERVICE EQUIPMENT OR THE VEHI-
CLE REFRIGERANT SYSTEM SHOULD NOT BE
PRESSURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR. SOME MIXTURES OF AIR AND
R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE
AT ELEVATED PRESSURES. THESE MIXTURES ARE
POTENTIALLY DANGEROUS, AND MAY RESULT IN
FIRE OR EXPLOSION CAUSING INJURY OR PROP-
ERTY DAMAGE.
Fig. 1 SPRING-LOCK COUPLER - TYPICAL
1 - MALE HALF SPRING-LOCK COUPLER
2 - FEMALE HALF SPRING-LOCK COUPLER
3 - SECONDARY CLIP
4 - CONNECTION INDICATOR RING
5 - COUPLER CAGE
6 - GARTER SPRING
7 - COUPLER CAGE
8-9O9RINGS
BR/BEPLUMBING 24 - 41
PLUMBING (Continued)

The refrigerant system will remain chemically sta-
ble as long as pure, moisture-free R-134a refrigerant
and refrigerant oil is used. Dirt, moisture, or air can
upset this chemical stability. Operational troubles or
serious damage can occur if foreign material is
present in the refrigerant system.
When it is necessary to open the refrigerant sys-
tem, have everything needed to service the system
ready. The refrigerant system should not be left open
to the atmosphere any longer than necessary. Cap or
plug all lines and fittings as soon as they are opened
to prevent the entrance of dirt and moisture. All lines
and components in parts stock should be capped or
sealed until they are to be installed.
All tools, including the refrigerant recycling equip-
ment, the manifold gauge set, and test hoses should
be kept clean and dry. All tools and equipment must
be designed for R-134a refrigerant.
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
If the air conditioning system is not cooling prop-
erly, determine if the refrigerant system is fully-
charged. (Refer to 24 - HEATING & AIR
CONDITIONING - DIAGNOSIS AND TESTING -
A/C PERFORMANCE) If the refrigerant system is
low or empty; a leak at a refrigerant line, connector
fitting, component, or component seal is likely.
An electronic leak detector designed for R-134a
refrigerant, or a fluorescent R-134a leak detection
dye and a black light are recommended for locating
and confirming refrigerant system leaks. Refer to the
operating instructions supplied by the equipment
manufacturer for proper care and use of this equip-
ment.
An oily residue on or near refrigerant system lines,
connector fittings, components, or component seals
can indicate the general location of a possible refrig-
erant leak. However, the exact leak location should
be confirmed with an electronic leak detector prior to
component repair or replacement.
To detect a leak in the refrigerant system with an
electronic leak detector, perform one of the following
procedures:
SYSTEM EMPTY
(1) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(2) Connect and dispense 0.283 kilograms (0.625
pounds or 10 ounces) of R-134a refrigerant into the
evacuated refrigerant system. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE - REFRIGERANT SYSTEM
CHARGE)
(3) Position the vehicle in a wind-free work area.
This will aid in detecting small leaks.
(4) With the engine not running, use a electronic
R-134a leak detector and search for leaks. Because
R-134a refrigerant is heavier than air, the leak detec-
tor probe should be moved slowly along the bottom
side of all refrigerant lines, connector fittings and
components.
(5) To inspect the evaporator coil for leaks, insert
the electronic leak detector probe into the center
instrument panel outlet. Set the blower motor switch
to the lowest speed position, and the mode control
switch in the recirculation mode.
SYSTEM LOW
(1) Position the vehicle in a wind-free work area.
This will aid in detecting small leaks.
(2) Bring the refrigerant system up to operating
temperature and pressure. This is done by allowing
the engine to run with the air conditioning system
turned on for five minutes.
(3) With the engine not running, use a electronic
R-134a leak detector and search for leaks. Because
R-134a refrigerant is heavier than air, the leak detec-
tor probe should be moved slowly along the bottom
side of all refrigerant lines, connector fittings and
components.
(4) To inspect the evaporator coil for leaks, insert
the electronic leak detector probe into the center
instrument panel outlet. Set the blower motor switch
to the lowest speed position, and the mode control
switch in the recirculation mode.
STANDARD PROCEDURE - A/C LINE
COUPLERS
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
REMOVAL
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
BR/BEPLUMBING 24 - 43
PLUMBING (Continued)

TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(2) Remove the secondary clip from the spring-lock
coupler.
(3) Fit the proper size A/C line disconnect tool
(Special Tool Kit 7193) over the spring-lock coupler
cage (Fig. 2).
(4) Close the two halves of the A/C line disconnect
tool around the spring-lock coupler.
(5) Push the A/C line disconnect tool into the open
side of the coupler cage to expand the garter spring.
Once the garter spring is expanded and while still
pushing the disconnect tool into the open side of the
coupler cage, pull on the refrigerant line attached to
the female half of the coupler fitting until the flange
on the female fitting is separated from the garter
spring and cage on the male fitting within the dis-
connect tool.
INSTALLATION
(1) Check to ensure that the garter spring is
located within the cage of the male coupler fitting,
and that the garter spring is not damaged.
(a) If the garter spring is missing, install a new
spring by pushing it into the coupler cage opening.
(b) If the garter spring is damaged, remove it
from the coupler cage with a small wire hook (DO
NOT use a screwdriver) and install a new garter
spring.
(2) Clean any dirt or foreign material from both
halves of the coupler fitting.(3) Install new O-rings on the male half of the cou-
pler fitting.
CAUTION: Use only the specified O-rings as they
are made of a special material for the R-134a sys-
tem. The use of any other O-rings may allow the
connection to leak intermittently during vehicle
operation.
(4) Lubricate the male fitting and O-rings, and the
inside of the female fitting with clean R-134a refrig-
erant oil. Use only refrigerant oil of the type recom-
mended for the compressor in the vehicle.
(5) Fit the female half of the coupler fitting over
the male half of the fitting.
(6) Push together firmly on the two halves of the
coupler fitting until the garter spring in the cage on
the male half of the fitting snaps over the flanged
end on the female half of the fitting.
(7) Ensure that the spring-lock coupler is fully
engaged by trying to separate the two coupler halves.
This is done by pulling the refrigerant lines on either
side of the coupler away from each other.
(8) Reinstall the secondary clip over the spring-
lock coupler cage.
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
When servicing the air conditioning system, a
R-134a refrigerant recovery/recycling/charging sta-
tion that meets SAE Standard J2210 must be used.
Contact an automotive service equipment supplier for
refrigerant recovery/recycling/charging equipment.
Refer to the operating instructions supplied by the
equipment manufacturer for proper care and use of
this equipment.
A manifold gauge set may be needed with some
recovery/recycling/charging equipment (Fig. 3). The
service hoses on the gauge set being used should
have manual (turn wheel), or automatic back-flow
valves at the service port connector ends. This will
prevent refrigerant from being released into the
atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
Fig. 2 REFRIGERANT LINE SPRING-LOCK
COUPLER DISCONNECT
24 - 44 PLUMBINGBR/BE
PLUMBING (Continued)

LOW PRESSURE GAUGE HOSE The low pressure
hose (Blue with Black stripe) attaches to the suction
service port. This port is located on the suction line
between the accumulator outlet and the compressor.
HIGH PRESSURE GAUGE HOSE The high pres-
sure hose (Red with Black stripe) attaches to the dis-
charge service port. This port is located on the
discharge line between the compressor and the con-
denser inlet.
RECOVERY/RECYCLING/EVACUATION/CHARG-
ING HOSE The center manifold hose (Yellow, or
White, with Black stripe) is used to recover, evacu-
ate, and charge the refrigerant system. When the low
or high pressure valves on the manifold gauge set
are opened, the refrigerant in the system will escape
through this hose.
STANDARD PROCEDURE - REFRIGERANT
RECOVERY
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
A R-134a refrigerant recovery/recycling/charging
station that meets SAE Standard J2210 must be
used to recover the refrigerant from an R-134a refrig-
erant system. Refer to the operating instructions sup-
plied by the equipment manufacturer for the proper
care and use of this equipment.
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
If the refrigerant system has been open to the
atmosphere, it must be evacuated before the system
can be charged. If moisture and air enters the system
and becomes mixed with the refrigerant, the com-
pressor head pressure will rise above acceptable
operating levels. This will reduce the performance of
the air conditioner and damage the compressor.
Evacuating the refrigerant system will remove the
air and boil the moisture out of the system at near
room temperature. To evacuate the refrigerant sys-
tem, use the following procedure:
(1) Connect a R-134a refrigerant recovery/recy-
cling/charging station that meets SAE Standard
J2210 and a manifold gauge set to the refrigerant
system of the vehicle.
(2) Open the low and high side valves and start
the charging station vacuum pump. When the suc-
tion gauge reads 88 kPa (26 in. Hg.) vacuum or
greater, close all of the valves and turn off the vac-
uum pump.
(a) If the refrigerant system fails to reach the
specified vacuum, the system has a leak that must
be corrected. (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - DIAGNOSIS AND
TESTING - REFRIGERANT SYSTEM LEAKS)
(b) If the refrigerant system maintains the spec-
ified vacuum for five minutes, restart the vacuum
pump, open the suction and discharge valves and
evacuate the system for an additional ten minutes.
(3) Close all of the valves, and turn off the charg-
ing station vacuum pump.
(4) The refrigerant system is now ready to be
charged with R-134a refrigerant. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
Fig. 3 MANIFOLD GAUGE SET - TYPICAL
1 - HIGH PRESSURE GAUGE
2 - VALVE
3 - VACUUM/REFRIGERANT HOSE (YELLOW W/ BLACK
STRIPE)
4 - HIGH PRESSURE HOSE (RED W/ BLACK STRIPE)
5 - LOW PRESSURE HOSE (BLUE W/ BLACK STRIPE)
6 - VALVE
7 - LOW PRESSURE GAUGE
BR/BEPLUMBING 24 - 45
PLUMBING (Continued)