2002 JEEP LIBERTY Accumulator

on the evaporator fins from freezing and obstructing
air conditioning system air flow.
The a/c low pressure switch contacts are open
when the suction pressure is approximately 141 kPa
(20.5 psi) or lower. The switch contacts will close
when the suction pressure rises to approximately 234
to 262 kPa (34 to 38 psi) or above. Lower ambient
temperatures, below approximately -1É C (30É F), will
also cause the switch contacts to open. This is due to
the pressure/temperature relationship of the refriger-
ant in the system.
The a/c low pressure switch is a factory-calibrated
unit. It cannot be adjusted or repaired and, if faulty
or damaged, it must be replaced.
DIAGNOSIS AND TESTING - A/C LOW
PRESSURE SWITCH
Before performing diagnosis of the a/c low pressure
switch, be certain that the switch is properly
installed on the accumulator fitting. If the switch is
too loose it may not open the Schrader-type valve in
the accumulator fitting, which will prevent the
switch from correctly monitoring the refrigerant sys-
tem pressure. Remember that lower ambient temper-
atures, below about -1É C (30É F), during cold
weather will open the switch contacts and prevent
compressor operation due to the pressure/tempera-
ture relationship of the refrigerant.
Also verify that the refrigerant system has the cor-
rect refrigerant charge. (Refer to 24 - HEATING &
AIR CONDITIONING - DIAGNOSIS AND TESTING
- A/C PERFORMANCE) and (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - SPECIFICA-
TIONS).
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information).
(1) Disconnect and isolate the battery negative
cable.
(2) Unplug the a/c low pressure switch wire har-
ness connector from the switch on the accumulator
fitting.
(3) Install a jumper wire between the two cavities
of the a/c low pressure switch wire harness connector.
(4) Connect a manifold gauge set to the refrigerant
system service ports. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM SERVICE
EQUIPMENT) and (Refer to 24 - HEATING & AIR
CONDITIONING - DESCRIPTION - REFRIGERANT
SYSTEM SERVICE PORT)
(5) Connect the battery negative cable.
(6) Place the A/C Heater mode control switch knob
in any A/C position and start the engine.
(7) Check for continuity between the two terminals
of the a/c low pressure switch. There should be con-
tinuity with a suction pressure reading of 262 kPa(38 psi) or above, and no continuity with a suction
pressure reading of 141 kPa (20.5 psi) or below. If
OK, test and repair the A/C switch sense circuit as
required. If not OK, replace the faulty switch.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Unplug the wire harness connector from the a/c
low pressure switch on the top of the accumulator
(Fig. 13).
(3) Unscrew the a/c low pressure switch from the
fitting on the top of the accumulator.
(4) Remove the O-ring seal from the accumulator
fitting and discard.
INSTALLATION
(1) Lubricate a new O-ring seal with clean refrig-
erant oil and install it on the accumulator fitting.
Use only the specified O-rings as they are made of a
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the com-
pressor in the vehicle. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/REFRIGERANT
OIL - DESCRIPTION)
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
KJCONTROLS 24 - 19
A/C LOW PRESSURE SWITCH (Continued)

(2) Install and tighten the a/c low pressure switch
on the accumulator fitting. The switch should be
hand-tightened onto the accumulator fitting.
(3) Plug the wire harness connector into the a/c
low pressure switch.
(4) Connect the battery negative cable.
BLEND DOOR ACTUATOR
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.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove A/C housing from vehicle(Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).
(3) Remove the screws that secure the blend door
actuator to the top of the HVAC housing. (Fig. 14).
(4) Remove the blend door actuator.
INSTALLATION
(1) Install the blend door actuator in place.
(2) Install and tighten the screws that secure the
blend door actuator to the housing. Tighten the
mounting screws to 2.4 ( .34) N´m (21 ( 3) in. lbs.).
(3) Install the HVAC housing into the vehicle(Re-
fer to 24 - HEATING & AIR CONDITIONING/DIS-
TRIBUTION/HVAC HOUSING - INSTALLATION).
(4) Install the blend door actuator electrical con-
nector from the wiring harness through the glove
box.
(5) Connect the battery negative cable.
BLOWER MOTOR RELAY
DESCRIPTION
The blower motor relay is a International Stan-
dards Organization (ISO)-type relay. The relay is a
electromechanical device that switches battery cur-
rent from a fuse in the Power Distribution Center
(PDC) directly to the blower motor. The relay is ener-
gized when the relay coil is provided a voltage signal
by the ignition switch. (Refer to 24 - HEATING &
AIR CONDITIONING/CONTROLS/BLOWER
MOTOR RELAY - DIAGNOSIS AND TESTING)
OPERATION
The blower motor relay is installed in a wire har-
ness connector that is secured to the passenger side
outboard end of the HVAC housing in the passenger
compartment, next to the HVAC wire harness con-
nector.
The blower motor relay cannot be repaired and, if
faulty or damaged, it must be replaced.
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)
24 - 20 CONTROLSKJ
A/C LOW PRESSURE SWITCH (Continued)

HVAC HOUSING
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.
(1) Disconnect and isolate the battery negative
cable.(2) Remove the instrument panel from the vehi-
cle(Refer to 23 - BODY/INSTRUMENT PANEL -
REMOVAL).
(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
refrigerant system. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT RECOVERY)
(4) Disconnect the liquid line refrigerant line fit-
ting from the evaporator inlet tube (Fig. 5). (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - A/C LINE COU-
PLERS)
(5) 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.
(6) Drain the engine cooling system(Refer to 7 -
COOLING - STANDARD PROCEDURE).
Fig. 5 HVAC CASE ASSEMBLY
1 - BLOWER MOTOR AND CAGE
2 - RECIRCULATION DOOR ACTUATOR LINKAGE
3 - RECIRCULATION DOOR VACUUM ACTUATOR
4 - CASE RETAINER SCREW
5 - BLEND DOOR ACTUATOR MOUNTING SCREWS
6 - ELECTRIC BLEND DOOR ACTUATOR
7 - ELECTRICAL CONNECTOR FOR BLEND DOOR ACTUATOR
8 - HEATER CORE RETAINER TABS (4) AND SCREWS (2)9 - HEATER CORE
10 - HVAC CASE RETAINER CLIP
11 - HEATER CORE INPUT AND OUTPUT CONNECTIONS
12 - EVAPORATOR CONNECTION FLANGE
13 - HVAC CASE RETAINER SCREWS
14 - HVAC HOUSING
KJDISTRIBUTION 24 - 33

PLUMBING
TABLE OF CONTENTS
page page
PLUMBING
DESCRIPTION - REFRIGERANT LINE.......38
WARNING
SERVICE WARNINGS..................39
CAUTION
SERVICE CAUTIONS..................39
CAUTION - REFRIGERANT HOSES/LINES/
TUBES PRECAUTIONS.................40
STANDARD PROCEDURE
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT..........40
STANDARD PROCEDURE - REFRIGERANT
RECOVERY..........................41
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE...................41
STANDARD PROCEDURE - REFRIGERANT
SYSTEM CHARGE.....................41
SPECIFICATIONS - CHARGE CAPACITY.....42
A/C COMPRESSOR
DESCRIPTION
DESCRIPTION........................42
DESCRIPTION - HIGH PRESSURE RELIEF
VALVE..............................42
OPERATION
OPERATION.........................42
OPERATION - HIGH PRESSURE RELIEF
VALVE..............................42
DIAGNOSIS AND TESTING - A/C
COMPRESSOR NOISE.................42
REMOVAL.............................43
INSTALLATION.........................44
A/C CONDENSER
DESCRIPTION.........................45
OPERATION...........................45
REMOVAL.............................45
INSTALLATION.........................46
A/C DISCHARGE LINE
REMOVAL.............................46INSTALLATION.........................47
A/C LIQUID LINE
REMOVAL.............................47
INSTALLATION.........................47
A/C SUCTION LINE
REMOVAL.............................48
INSTALLATION.........................49
A/C EVAPORATOR
DESCRIPTION.........................49
OPERATION...........................49
REMOVAL.............................49
INSTALLATION.........................49
A/C ORIFICE TUBE
DESCRIPTION.........................50
OPERATION...........................50
REMOVAL.............................50
INSTALLATION.........................50
ACCUMULATOR
DESCRIPTION.........................51
OPERATION...........................51
REMOVAL.............................51
INSTALLATION.........................51
HEATER CORE
DESCRIPTION.........................52
OPERATION...........................52
REMOVAL.............................52
INSTALLATION.........................53
REFRIGERANT
DESCRIPTION.........................53
OPERATION...........................53
REFRIGERANT OIL
DESCRIPTION.........................53
OPERATION...........................54
STANDARD PROCEDURE - REFRIGERANT
OIL LEVEL...........................54
PLUMBING
DESCRIPTION - REFRIGERANT LINE
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 on
this vehicle. This nylon tube helps to further containthe 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.
24 - 38 PLUMBINGKJ

CAUTION - REFRIGERANT HOSES/LINES/
TUBES PRECAUTIONS
Kinks or sharp bends in the refrigerant plumbing will
reduce the capacity of the entire system. High pressures
are produced in the system when it is operating.
Extreme care must be exercised to make sure that all
refrigerant system connections are pressure tight.
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. Sharp bends will reduce the
flow of refrigerant. The flexible hose lines should be
routed so they are at least 80 millimeters (3 inches)
from the exhaust manifold. It is a good practice to
inspect all flexible refrigerant system hose lines at
least once a year to make sure they are in good con-
dition and properly routed.
There are two types of refrigerant fittings:
²
All fittings with O-rings need to be coated with
refrigerant oil before installation. Use only O-rings that
are the correct size and approved for use with R-134a
refrigerant. Failure to do so may result in a leak.
²Unified plumbing connections with gaskets can-
not be serviced with O-rings. The gaskets are not
reusable and new gaskets do not require lubrication
before installing.
Using the proper tools when making a refrigerant
plumbing connection is very important. Improper
tools or improper use of the tools can damage the
refrigerant fittings. Always use two wrenches when
loosening or tightening tube fittings. Use one wrench
to hold one side of the connection stationary, while
loosening or tightening the other side of the connec-
tion with a second wrench.
The refrigerant must be recovered completely from
the system before opening any fitting or connection.
Open the fittings with caution, even after the refrig-
erant has been recovered. If any pressure is noticed
as a fitting is loosened, tighten the fitting and
recover the refrigerant from the system again.
Do not discharge refrigerant into the atmosphere.
Use an R-134a refrigerant recovery/recycling device
that meets SAE Standard J2210.
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.
STANDARD PROCEDURE
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. 1). 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.
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.
24 - 40 PLUMBINGKJ
PLUMBING (Continued)

(3) To duplicate a high-ambient temperature condi-
tion (high head pressure), restrict the air flow
through the condenser. Install a manifold gauge set
to be certain that the discharge pressure does not
exceed 2760 kPa (400 psi).
(4) Check the refrigerant system plumbing for
incorrect routing, rubbing or interference, which can
cause unusual noises. Also check the refrigerant lines
for kinks or sharp bends that will restrict refrigerant
flow, which can cause noises. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAU-
TION)
(5) If the noise is from opening and closing of the
high pressure relief valve, evacuate and recharge the
refrigerant system. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM EVACUATE)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - REFRIG-
ERANT SYSTEM CHARGE) If the high pressure
relief valve still does not seat properly, replace the
compressor.
(6) If the noise is from liquid slugging on the suc-
tion line, replace the accumulator. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/AC-
CUMULATOR - REMOVAL) Check the refrigerant oil
level and the refrigerant system charge. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
REFRIGERANT OIL - STANDARD PROCEDURE)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - SPECIFICATIONS - CHARGE
CAPACITY) If the liquid slugging condition continues
following accumulator replacement, replace the com-
pressor. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C COMPRESSOR -
REMOVAL)
(7) If the noise continues, replace the compressor
and repeat Step 1.
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)
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.
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)(2) Disconnect and isolate the battery negative
cable.
(3) Remove the serpentine drive belt(Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Unplug the compressor clutch coil wire harness
connector.
(5) Remove the suction and discharge refrigerant
line manifold from the compressor. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
SUCTION LINE - REMOVAL) (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - REMOVAL) Install plugs in, or
tape over all of the opened refrigerant fittings.
(6) Remove the bolts that secure the compressor to
the mounting bracket (Fig. 2) or (Fig. 3) or (Fig. 4).
(7) Remove the compressor from the mounting
bracket.
Fig. 2 A/C COMPRESSOR - 2.4L ENGINE
1 - COMPRESSOR BOLT
2 - COMPRESSOR BOLT
3 - COMPRESSOR CLUTCH AND PULLY
4 - IDLER PULLEY
5 - ENGINE BLOCK
6 - A/C COMPRESSOR
KJPLUMBING 24 - 43
A/C COMPRESSOR (Continued)

INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
(1) Install the 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)

(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)