Dodge Dakota (R1). Manual - part 798

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: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) AND (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION) BEFORE PERFORMING THE FOLLOWING
OPERATION.

CAUTION: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
condenser and radiator. The air seals must be rein-
stalled in their proper locations in order for the air
conditioning and engine cooling systems to per-
form as designed.

(1) Disconnect and isolate the battery negative

cable.

(2) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT

STANDARD

PROCEDURE).

(3) Disconnect the refrigerant line fitting that

secures the discharge line to the condenser inlet (Fig.
3). Install plugs in, or tape over all of the opened
refrigerant line fittings.

(4) Disconnect the refrigerant line fitting that

secures the liquid line to the condenser outlet. Install
plugs in, or tape over all of the opened refrigerant
line fittings.

(5) Remove the two screws that secure the radiator

and fan shroud module to the inside of the upper
radiator crossmember.

(6) Remove the condenser cooling module from the

vehicle.

INSTALLATION

WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) AND (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION) BEFORE PERFORMING THE FOLLOWING
OPERATION.

(1) Remove the plugs or tape from the refrigerant

line fittings on the liquid line and the condenser out-
let. Connect the liquid line to the condenser outlet.
Tighten the fitting to 22.59 ±3.39 N·m (200 ±30 in.
lbs.).

(2) Remove the plugs or tape from the refrigerant

line fittings on the discharge line and the condenser
inlet. Connect the discharge line to the condenser
inlet. Tighten the fitting to 22.59 ±3.39 N·m (200 ±30
in. lbs.).

(3) Check that all of the condenser and radiator

air seals are in their proper locations.

(4) Connect the battery negative cable.
(5) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE).

(6) Charge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE).

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.

Fig. 3 Condenser Line Fittings

1 - DISCHARGE LINE
2 - CONDENSOR
3 - LIQUID LINE

24 - 38

PLUMBING

A/C CONDENSER (Continued)

A/C DISCHARGE LINE

REMOVAL

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.

WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) AND (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION) BEFORE PERFORMING THE FOLLOWING
OPERATION.

(1) Disconnect and isolate the battery negative

cable.

(2) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT

STANDARD

PROCEDURE).

(3) Unplug the wire harness connector from the a/c

pressure transducer switch.

(4) Remove the fasteners and disconnect the refrig-

erant line couplers at the condenser and the accumu-
lator

(Refer

HEATING

AIR

CONDITIONING/PLUMBING - REMOVAL). Install
plugs in, or tape over all of the opened refrigerant
line fittings.

(5) Remove the fastener that secures the refriger-

ant line support bracket near the compressor.

(6) Remove the screw that secures the refrigerant

line manifold to the compressor. Install plugs in, or
tape over all of the opened refrigerant line fittings.

(7) Remove the suction and discharge line assem-

bly from the vehicle.

INSTALLATION

Any kinks or sharp bends in the refrigerant plumb-

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-

WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) AND (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION) BEFORE PERFORMING THE FOLLOWING
OPERATION.

(1) Remove the tape or plugs from all of the refrig-

erant line fittings. Install the refrigerant line cou-
plers to the condenser and the accumulator (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- INSTALLATION). Tighten the fasteners to 22 ±3.38
N·m (200 ±30 in. lbs.).

(2) Install the refrigerant line manifold to the com-

pressor. Tighten the mounting screw to 22 N·m (200
in. lbs.).

(3) Install the fastener that secures the refrigerant

line support bracket near the compressor. Tighten
the mounting screw to 6.77 ±1.7 N·m (60 ±15 in.
lbs.).

(4) Plug in the wire harness connector to the pres-

sure transducer switch.

(5) Connect the battery negative cable.
(6) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE).

(7) Charge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE).

A/C EVAPORATOR

DESCRIPTION

The evaporator coil is located in the heater-A/C

housing, under the instrument panel. The evaporator
coil is positioned in the heater-A/C housing so that
all air that enters the housing must pass over the
fins of the evaporator before it is distributed through
the system 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.

PLUMBING

24 - 39

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 high-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

SERVICE.

FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.

(1) Remove the heater-A/C housing from the vehi-

cle (Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL).

(2) Remove the upper housing cover (Refer to 24 -

HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - DISASSEMBLY).

(3) Lift the evaporator coil out of the heater-A/C

housing.

INSTALLATION

FURTHER

DIAGNOSIS

SERVICE.

FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.

NOTE: If the evaporator is replaced, add 60 millili-
ters (2 fluid ounces) of refrigerant oil to the refrig-
erant system.

(1) Insert the evaporator coil into the bottom of the

heater-A/C housing.

(2) Reassemble the heater-A/C housing (Refer to

24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION/HVAC HOUSING - ASSEMBLY).

(3) Install the heater-A/C housing into the vehicle

(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC

HOUSING

INSTALLA-

TION).

A/C ORIFICE TUBE

DESCRIPTION

The fixed orifice tube is installed in the liquid line

between the outlet of the condenser and the inlet of
the evaporator. The fixed orifice tube is located near
the front end of the rear half of the two-piece liquid
line. It is accessed for service by separating the tube
fitting that joins the two halves of the liquid line.

OPERATION

The inlet end of the fixed orifice tube has a nylon

mesh filter screen, which filters the refrigerant and
helps to reduce the potential for blockage of the
metering orifice by refrigerant system contaminants
(Fig. 4). The outlet end of the tube has a nylon mesh
diffuser screen. The O-rings on the plastic body of
the fixed orifice tube seal the tube to the inside of
the liquid line and prevent the refrigerant from
bypassing the fixed metering orifice.

The fixed orifice tube is used to meter the flow of

liquid refrigerant into the evaporator coil. The high-
pressure

liquid

refrigerant

from

the

condenser

expands into a low-pressure liquid as it passes
through the metering orifice and diffuser screen of
the fixed orifice tube.

The fixed orifice tube cannot be repaired and, if

faulty or plugged, it must be replaced.

Fig. 4 Fixed Orifice Tube - Typical

1 - DIFFUSER SCREEN
2 - “O” RINGS
3 - INLET FILTER SCREEN
4 - ORIFICE

24 - 40

PLUMBING

A/C EVAPORATOR (Continued)

REMOVAL

WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) AND (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION) BEFORE PERFORMING THE FOLLOWING
OPERATION.

(1) Disconnect and isolate the battery negative

cable.

(2) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT

STANDARD

PROCEDURE).

(3) Disconnect the liquid line refrigerant line fas-

tener at the condenser outlet tube (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
REMOVAL). Install plugs in, or tape over all of the
opened refrigerant line fittings.

CAUTION: Always use two wrenches when loosen-
ing or tightening tube fittings. Use one wrench to
hold one side of the connection stationary, while
loosening or tightening the other side of the con-
nection with a second wrench.

(4) Remove the front half of the liquid line from

the rear half by disconnecting it at the tube fitting.
Install plugs in, or tape over all of the opened refrig-
erant line tube fittings.

(5) Remove the fixed orifice tube from the rear half

of the liquid line using a pair of needle nose pliers.
Note the orientation of the fixed orifice tube for cor-
rect reinstallation.

INSTALLATION

WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) AND (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION) BEFORE PERFORMING THE FOLLOWING
OPERATION.

(1) Insert the fixed orifice tube into the rear half of

the liquid line. Be certain that it is properly oriented
(Fig. 5).

(2) Remove the tape or plugs from all of the refrig-

erant line tube fittings. Install a new O-ring on the
liquid line tube fitting. Connect and tighten the tube
fitting on the front half of the liquid line to the tube
fitting on the rear half of the liquid line (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
INSTALLATION).

(3) Remove the tape or plugs from all of the refrig-

erant line fittings. Install the front half of the liquid
line to the condenser outlet tube. Tighten the fas-
tener to 22.6 ±3.39 N·m (200 ±30 in. lbs.).

(4) Connect the battery negative cable.
(5) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE).

(6) Charge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE).

ACCUMULATOR

DESCRIPTION

The accumulator is mounted in the engine com-

partment between the a/c evaporator 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. 6).

REMOVAL

WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) AND (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION) BEFORE PERFORMING THE FOLLOWING
OPERATION.

(1) Disconnect and isolate the battery negative

cable.

(2) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT

STANDARD

PROCEDURE).

(3) Unplug the wire harness connector from the

loss of pressure switch.

Fig. 5 Fixed Orifice Tube - Typical

1 - DIFFUSER SCREEN
2 - “O” RINGS
3 - INLET FILTER SCREEN
4 - ORIFICE

PLUMBING

24 - 41

A/C ORIFICE TUBE (Continued)

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