Jeep Wrangler TJ. Manual - part 601

(3) Align the radiator mounting brackets to the

grille panel and install the six bolts that secure the
radiator to the grille panel. Tighten the bolts to 8
N·m (72 in. lbs.).

(4) Raise and support the vehicle.
(5) Position the lower condenser/radiator air seal

out of the way and install the two bolts that secure
the lower condenser mounting bracket to the bottom
of the grille panel. Tighten the bolts to 5 N·m (44 in.
lbs.).

(6) Lower the vehicle.
(7) Remove the tape or plugs from the discharge

and liquid line fittings and the condenser ports.

(8) Lubricate new rubber O-ring seals with clean

refrigerant oil and install them onto the discharge
and liquid 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 recom-
mended for the A/C compressor in the vehicle.

(9) Install the discharge and liquid lines onto the

condenser tapping block.

(10) Install the nuts that secures the discharge

and liquid lines to the condenser tapping block.
Tighten the nuts to 12 N·m (105 in. lbs.).

(11) If equipped, install the upper condenser/radia-

tor air seal.

(12) Install the radiator cooling fan and fan shroud

(Refer to 7 - COOLING/ENGINE/FAN DRIVE VIS-
COUS CLUTCH - INSTALLATION).

(13) Connect the upper radiator hose to the radia-

tor and install the hose clamp (Refer to 7 - COOL-
ING - OPERATION - HOSE CLAMPS).

(14) Install the coolant recovery container (Refer to

COOLING/ENGINE/COOLANT

RECOVERY

CONTAINER - INSTALLATION).

(15) Reconnect the battery negative cable.
(16) Fill the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILLING)

(17) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).

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

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).

A/C DISCHARGE LINE

DESCRIPTION

The A/C discharge line is the refrigerant line that

carries refrigerant from the A/C compressor to the
A/C condenser. The A/C discharge line includes the
high-side service port.

The A/C discharge line on models equipped with

the 2.4L engine include a fitting for the A/C pressure
transducer. For more information refer to 24 - HEAT-
ING

AIR

CONDITIONING/CONTROLS/A/C

PRESSURE TRANSDUCER - DESCRIPTION.

The A/C discharge line on models equipped with

the 4.0L engine include a fitting for the A/C high
pressure switch. For more information refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS/A/C
HIGH PRESSURE SWITCH - DESCRIPTION.

CAUTION: Use only seals specified for the vehicle.
Failure to use the correct seals will cause the refrig-
erant system connections to leak.

The A/C discharge line has no serviceable parts

except for the O-ring seals and high-side service port
valve and it’s protective cap.

If the A/C discharge line is found to be leaking or

is damaged, it must be replaced.

REMOVAL

2.4L ENGINE

WARNING: Refer to the applicable warnings and
cautions for this system before performing the fol-
lowing operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTIONS). Failure to follow the warnings and cau-
tions could result in possible personal injury or
death.

(1) Disconnect and isolate the negative battery

cable.

(2) Recover the refrigerant from the refrigerant

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

STANDARD

PROCEDURE

REFRIGERANT SYSTEM RECOVERY).

(3) Disconnect the wire harness connector from the

A/C pressure transducer located on the A/C discharge
line (Fig. 10).

(4) Remove the nut that secures the A/C discharge

line to the A/C compressor.

(5) Disconnect the A/C discharge line from the A/C

compressor and remove and discard the O-ring seal.

(6) Install plug in, or tape over the opened dis-

charge line fitting and the compressor port.

(7) Remove the nut that secures theA/C discharge

line to the A/C condenser.

(8) Disconnect the A/C discharge line from the A/C

condenser and remove discard the O-ring seal.

(9) Install plug in, or tape over the opened dis-

charge line fitting and the condenser port.

24 - 70

PLUMBING

A/C CONDENSER (Continued)

(10) Remove the A/C discharge line from the

engine compartment and if required, remove the A/C
pressure transducer from the A/C discharge line.

4.0L ENGINE

(1) Disconnect and isolate the negative battery

cable.

(2) Recover the refrigerant from the refrigerant

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

STANDARD

PROCEDURE

REFRIGERANT SYSTEM RECOVERY).

(3) Disconnect the wire harness connector from the

A/C high pressure switch located on the A/C dis-
charge line (Fig. 11).

(4) Remove the nut that secures the refrigerant

line support bracket to the top of the engine and
remove the discharge line from the bracket.

(5) Remove the nut that secures the A/C discharge

line to the A/C compressor.

(6) Disconnect the A/C discharge line from the A/C

compressor and remove and discard the O-ring seal.

(7) Install plug in, or tape over the opened dis-

charge line fitting and the compressor port.

(8) Remove the nut that secures the A/C discharge

line to the A/C condenser.

(9) Disconnect the A/C discharge line from theA/C

condenser and remove discard the O-ring seal.

(10) Install plug in, or tape over the opened dis-

charge line fitting and the condenser port.

(11) Remove the A/C discharge line from the

engine compartment and if required, remove the A/C
high pressure switch from the A/C discharge line.

INSTALLATION

2.4L ENGINE

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.

Fig. 10 A/C Discharge Line - 2.4L Engine

1 - NUT
2 - A/C DISCHARGE LINE
3 - WIRE HARNESS CONNECTOR
4 - A/C PRESSURE TRANSDUCER
5 - NUT
6 - ACCUMULATOR
7 - A/C SUCTION LINE (FRONT SECTION)
8 - NUT (4)
9 - A/C SUCTION LINE (REAR SECTION)
10 - SECONDARY RETAINING CLIP
11 - A/C CONDENSER
12 - A/C COMPRESSOR

Fig. 11 A/C Discharge Line - 4.0L LHD shown, RHD

similar

1 - REFRIGERANT LINE RETAINING CLIP (2)
2 - A/C LIQUID LINE
3 - SECONDARY RETAINING CLIP
4 - A/C SUCTION LINE (FRONT SECTION)
5 - NUT
6 - A/C DISCHARGE LINE
7 - A/C HIGH PRESSURE SWITCH
8 - NUT
9 - A/C COMPRESSOR
10 - NUT
11 - REFRIGERANT LINE BRACKET
12 - NUT
13 - NUT
14 - A/C CONDENSER

PLUMBING

24 - 71

A/C DISCHARGE LINE (Continued)

(1) If removed, install the A/C pressure transducer

onto the A/C discharge line. Hand-tighten the trans-
ducer securely.

(2) Position the A/C discharge line into the engine

compartment.

(3) Remove the tape or plugs from the condenser

port and the discharge line fitting.

(4) Lubricate a new rubber O-ring seal with clean

refrigerant oil and install it on the discharge line fit-
ting. 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 con-

denser.

(6) Install the nut that secures the A/C discharge

line to the A/C condenser. Tighten the nut to 12 N·m
(105 in. lbs.).

(7) Remove the tape or plugs from the compressor

port and the discharge line fitting.

(8) Lubricate a new rubber O-ring seal with clean

(9) Connect the A/C discharge line to the A/C com-

pressor.

(10) Install the bolt that secures the A/C discharge

line to the A/C compressor. Tighten the bolt to 25
N·m (18 ft. lbs.).

(11) Connect the wire harness connector to the A/C

pressure transducer.

(12) Reconnect the negative battery cable.
(13) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).

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

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).

4.0L ENGINE

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.

(1) If removed, install the A/C high pressure

switch onto the A/C discharge line. Hand-tighten the
switch securely.

(2) Position the A/C discharge line into the engine

compartment.

(3) Remove the tape or plugs from the condenser

port and the discharge line fitting.

(4) Lubricate a new rubber O-ring seal with clean

(5) Connect the A/C discharge line to the A/C con-

denser.

(6) Install the nut that secures the A/C discharge

line to the A/C condenser. Tighten the nut to 12 N·m
(105 in. lbs.).

(7) Remove the tape or plugs from the compressor

port and the discharge line fitting.

(8) Lubricate a new rubber O-ring seal with clean

(9) Connect the A/C discharge line to the A/C com-

pressor.

(10) Install the bolt that secures the A/C discharge

line to the A/C compressor. Tighten the bolt to 25
N·m (18 ft. lbs.).

(11) Install the A/C discharge line into the refrig-

erant line bracket and install the retaining nut.
Tighten the nut to 5 N·m (44 in. lbs.).

(12) Connect the wire harness connector to the A/C

high pressure switch.

(13) Reconnect the negative battery cable.
(14) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).

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

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).

A/C EVAPORATOR

DESCRIPTION

The A/C evaporator (Fig. 12) for the heating-A/C

system is located within the HVAC housing, behind
the instrument panel. The A/C evaporator is posi-
tioned in the HVAC housing so that all air entering
the housing must pass over the evaporator fins
before it is distributed through the heating-A/C sys-
tem ducts and outlets. However, air passing over the
evaporator fins will only be conditioned when the A/C
compressor is engaged and circulating refrigerant
through the A/C evaporator.

The A/C evaporator tubes are connected and sealed

to the A/C liquid and suction lines by use of rubber
O-rings and quick-connect type fittings

24 - 72

PLUMBING

A/C DISCHARGE LINE (Continued)

The A/C evaporator can only be serviced by remov-

ing and disassembling the HVAC housing.

OPERATION

Refrigerant enters the A/C evaporator from the A/C

orifice tube as a low-temperature, low-pressure mix-
ture of liquid and gas. As air flows over the fins of
the A/C 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 refriger-
ant to boil and vaporize. The refrigerant becomes a
low-pressure gas when it leaves the A/C evaporator.

The A/C evaporator cannot be repaired and, if

faulty or damaged, it must be replaced.

REMOVAL

(1) Remove the HVAC housing (Refer to 24 -

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

(2) Disassemble the HVAC housing as necessary to

access the A/C evaporator (Refer to 24 - HEATING &
AIR

CONDITIONING/DISTRIBUTION/HVAC

HOUSING - DISASSEMBLY).

(3) Carefully lift the A/C evaporator and insulator

out of the lower half of the HVAC housing (Fig. 13).

(4) If required, remove the rubber grommet and

the foam insulator from the A/C evaporator. If the
insulator is deformed or damaged, it must be
replaced.

INSTALLATION

NOTE: If the A/C evaporator is being replaced, add
45 milliliters (1.5 fluid ounces) of refrigerant oil to
the refrigerant system. Use only refrigerant oil of

the type recommended for the A/C compressor in
the vehicle.

(1) If removed, install the foam insulator over the

A/C evaporator. If the insulator is deformed or dam-
aged, it must be replaced.

(2) Install the A/C evaporator into the lower half of

the HVAC housing. Make sure that the evaporator
drain within the HVAC housing is clean and unre-
stricted and that the foam insulator and rubber
grommet are properly installed.

(3) Assemble the HVAC housing (Refer to 24 -

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

(4) Install the HVAC housing (Refer to 24 - HEAT-

ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).

A/C ORIFICE TUBE

DESCRIPTION

The fixed A/C orifice tube is installed in the section

of the A/C liquid line closest to the A/C condenser
and provides a restriction in the liquid refrigerant
line between the A/C condenser and the A/C evapora-
tor. This restriction established the pressure differen-
tial between the high and low-pressure sides of the
A/C system.

The inlet end of the fixed A/C orifice tube has a

nylon mesh filter screen, which filters the refrigerant

Fig. 12 A/C Evaporator - Typical

1 - A/C EVAPORATOR

Fig. 13 A/C Evaporator - Typical

1 - A/C EVAPORATOR
2 - RUBBER GROMMET
3 - CONDENSATE DRAIN TUBE
4 - FOAM INSULATOR

PLUMBING

24 - 73

A/C EVAPORATOR (Continued)

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