REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the A/C system-
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE).
(3) Disconnect the the A/C lines from the expan-
sion valve. Cap or tape over the open A/C lines.
(4) Remove the lines from the expansion valve(Re-
fer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/LIQUID LINE - REMOVAL), (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
LIQUID LINE - REMOVAL), (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - REMOVAL) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - REMOVAL).
(5) Remove the expansion valve retainer screw
from the expansion valve.
(6) Remove the expansion valve.
(7) Remove the expansion valve gasket.
INSTALLATION
(1) Install a NEW gasket and install the eapansion
valve to the evaporator.
(2) Install the expansion valve bolts and tighten to
11 N´m (100 in. lbs.).
(3) Install NEW seals on the A/C lines and install
the lines to the expansion valve(Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C DIS-
CHARGE LINE - INSTALLATION), (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - INSTALLATION), (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
LIQUID LINE - INSTALLATION) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
LIQUID LINE - INSTALLATION).
(4) Evacuate the A/C system(Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
(5) Recharge the A/C system(Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
(6) Connect the battery negative cable.
LIQUID 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) The liquid line is serviced as an integral part of
the receiver/drier assembly(Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/RECEIVER /
DRIER - REMOVAL) or (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/RECEIVER /
DRIER - REMOVAL).
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) The liquid line is service as an integral part of
the receiver/drier assembly(Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/RECEIVER /
DRIER - REMOVAL).
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) The liquid line is serviced as an integral part of
the receiver/drier assembly(Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/RECEIVER /
DRIER - INSTALLATION) or (Refer to 24 - HEAT-
24 - 66 PLUMBINGWJ
A/C EXPANSION VALVE (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)
