INSTALLATION
2.8L DIESEL ENGINE
CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL). Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.
NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL).
NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals could result in a refrigerant system leak.
NOTE: LHD model shown in illustrations. RHD model similar.
1. If servicing only the rear section of the A/C suction line, go to STEP 13.
2. Position the front section of the A/C suction line (3) into the engine compartment.
3. Remove the tape or plugs from the discharge line fitting and compressor port.
4. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
5. Connect the A/C discharge line to the A/C compressor (4) and install the retaining bolt (2). Tighten the bolt to 12 N·m (106 ft. lbs.).
6. Install the front skid plate (refer to 13 - FRAME & BUMPERS/FRAME/FRONT SKID PLATE - INSTALLATION).
7. Lower the vehicle.
8. Engage the retaining clip (7) to the top of the fan shroud (6).
9. Remove the tape or plugs from the discharge line fitting and accumulator port.
10. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
11. Connect the front section of the A/C suction line to the A/C accumulator (3) and install the retaining nut (2). Tighten the nut to 12.5 N·m (110 in. lbs.).
12. If servicing only the front section of the A/C suction line, go to STEP 20.
13. Remove the tape or plugs from the opened refrigerant line fittings and the accumulator and evaporator ports.
14. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
15. Connect the rear section of the A/C suction line (9) to the A/C accumulator (10) and install the retaining nut (1). Tighten the nut to 12 N·m (110 in. lbs.).
16. On LHD models, connect the spring-lock coupler that secures the rear section of the A/C suction line to the evaporator outlet tube (6) and install the secondary retaining clip (4) (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/COUPLER-REFRIGERANT LINE - INSTALLATION).
17. On RHD models, connect the rear section of the A/C suction line to the A/C evaporator and install the retaining nut. Tighten the nut to 12 N·m (110 in. lbs.).
18. Install the two nuts (7) that secure the accumulator bracket (8) to the dash panel (5). Tighten the nuts to 4.5 N·m (40 in. lbs.).
19. Connect the wire lead and connector (3) to the A/C low pressure switch (2).
20. Reconnect the negative battery cable.
21. Evacuate the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
22. Adjust the refrigerant oil level (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL).
23. Charge the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
3.7L ENGINE
CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL). Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.
NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL).
NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals could result in a refrigerant system leak.
NOTE: LHD model shown in illustrations. RHD model similar.
1. Position the front section of the A/C suction line (2) into the engine compartment.
2. Remove the tape or plugs from the opened refrigerant line fittings and the accumulator and compressor ports.
3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
4. Connect the front section of the A/C suction line to the A/C compressor (3) and install the retaining nut (1). Tighten the nut to 12 N·m (105 in. lbs.).
5. Connect the front section of the A/C suction line (11) to the A/C accumulator (10) and install the retaining nut (1). Tighten the nut to 12 N·m (110 in. lbs.).
6. If servicing the front section of the A/C suction line only, go to STEP 14.
7. Remove the tape or plugs from all of the opened refrigerant line fittings and the accumulator and evaporator ports.
8. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. 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 A/C compressor in the vehicle.
9. Connect the rear section of the A/C suction line (9) to the A/C accumulator and install the retaining nut. Tighten the nut to 12 N·m (110 in. lbs.).
10. On LHD models, connect the spring-lock coupler that secures the rear section of the A/C suction line to the evaporator outlet tube (6) and install the secondary retaining clip (4) (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/COUPLER-REFRIGERANT LINE - INSTALLATION).
11. On RHD models, connect the rear section of the A/C suction line to the A/C evaporator and install the retaining nut. Tighten the nut to 12 N·m (110 in. lbs.).
12. Install the two nuts (7) that secure the accumulator bracket to the dash panel (5). Tighten the nuts to 4.5 N·m (40 in. lbs.).
13. Connect the wire lead and connector (3) to the A/C low pressure switch (2).
14. Reconnect the negative battery cable.
15. Evacuate the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
16. Adjust the refrigerant oil level (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL).
17. Charge the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).