Dodge Dakota (R1). Manual — part 803
INSTALLATION
CAUTION: Never let the internal components of the
accumulator be exposed to the atmosphere for any
length of time. The accumulator contains moisture
absorbing material that can be damaged by not
plugging the refrigerant line openings during any
service procedure.
(1) Install the accumulator in its mounting bracket
and tighten clamp retaining screw.
(2) Uncap refrigerant lines and clean / inspect the
sealing O-rings for any damage such as cracked,
torn, distorted or brittle condition. Replace O-rings if
necessary.
NOTE: Only use approved refrigerant oil for the
type of refrigerant used in the system to lubricate
O-rings during the assembly process.
(3) Lubricate the O-rings and install refrigerant
lines on the accumulator. Torque the retaining fas-
teners to 33 N·m (25 ft. lbs.).
(4) Thread the low pressure cycling clutch switch
in the accumulator. Hand tighten only.
(5) Connect the low pressure cycling clutch switch
connector.
NOTE: If the accumulator is being replaced, add 120
milliliters (4 fluid ounces) of refrigerant oil to the
system. Only use approved refrigerant oil for the
type of refrigerant used in the system
(6) Evacuate and Charge the refrigerant system-
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT
-
STANDARD
PROCEDURE) and (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE).
(7) Connect the negative battery cable.
(8) Check the accumulator and refrigerant lines at
the accumulator for any refrigerant leaks.
24a - 10
ACCUMULATOR
R1
ACCUMULATOR (Continued)
A/C DISCHARGE LINE
TABLE OF CONTENTS
page
page
A/C DISCHARGE LINE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
A/C DISCHARGE LINE
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Recover the refrigerant from the refrigerant
system(Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT
-
STANDARD
PROCEDURE).
(3) Remove the two upper condenser retaining
bolts.
(4) Remove the condenser refrigerant line support
bracket.
(5) Remove the secondary locking clip from the dis-
charge line at the condenser (Fig. 1).
(6) Disconnect the discharge refrigerant line from
the condenser(Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING/REFRIGERANT
LINE
COUPLER - REMOVAL). Cap/Cover all refrigerant
line openings.
(7) Remove the discharge line retaining bolt at the
compressor (Fig. 1). Cap/Cover opening at compres-
sor.
(8) Remove the refrigerant line support bracket
retaining nuts.
(9) Spread line brackets and remove the discharge
line from the vehicle.
Fig. 1 2.5L Diesel Refrigerant Line Position & Orientation
1 - SUCTION LINE
2 - DISCHARGE LINE
R1
A/C DISCHARGE LINE
24a - 11
INSTALLATION
(1) Position replacement discharge line in the sup-
port brackets and install retaining nuts. Torque to 22
N·m (196 in. lbs.).
(2) Uncap refrigerant line and clean / inspect the
sealing O-rings for any damage such as cracked,
torn, distorted or brittle condition. Replace O-rings if
necessary.
NOTE: Only use approved refrigerant oil for the
type of refrigerant used in the system to lubricate
O-rings during the assembly process.
(3) Lubricate all O-rings and install the discharge
line at the compressor. Torque to 33 N·m (25 ft. lbs.).
(4) Connect the discharge line on the condenser-
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT
LINE
COUPLER
-
INSTALLATION).
Cap/Cover
all
refrigerant
line
openings.
(5) Install the secondary locking clip on the dis-
charge line.
(6) Install the condenser refrigerant line support
bracket.
(7) Install the two upper condenser retaining bolts.
Torque to 10.7 N·m (95 in. lbs.).
(8) Evacuate and Charge the refrigerant system-
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT
-
STANDARD
PROCEDURE) and (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/REFRIGERANT
-
STANDARD PROCEDURE).
(9) Connect the negative battery cable.
(10) Check the discharge line and connections for
any refrigerant leaks.
24a - 12
A/C DISCHARGE LINE
R1
A/C DISCHARGE LINE (Continued)
LIQUID LINE
TABLE OF CONTENTS
page
page
LIQUID LINE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LIQUID LINE
REMOVAL
(1) Disconnect and isolate the negative battery cable.
(2) Recover the refrigerant from the refrigerant
system(Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT
-
STANDARD
PROCEDURE).
(3) Remove the air filter assembly from the vehicle.
(4) Remove the secondary locking clip from the liq-
uid line at the condenser.
(5) Disconnect the liquid refrigerant line from the
condenser(Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT LINE COUPLER -
REMOVAL). Cap/Cover all refrigerant line openings.
(6) Disconnect the horn electrical.
(7) Disconnect the liquid line coupler (Fig. 1).
(8) Remove
the
EGR
solenoid
and
mounting
bracket from the coolant bottle.
(9) Remove the secondary locking clip from the liq-
uid line at the evaporator.
(10) Disconnect the liquid refrigerant line from the
evaporator(Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT LINE COUPLER -
REMOVAL). Cap/Cover all refrigerant line openings.
(11) Disengage the liquid line from its mounting clips.
(12) Remove the liquid line from the vehicle.
INSTALLATION
(1) Position the liquid line in the engine compart-
ment.
(2) Uncap refrigerant lines and clean / inspect the
sealing O-rings for any damage such as cracked,
torn, distorted or brittle condition. Replace O-rings if
necessary.
NOTE: Only use approved refrigerant oil for the
type of refrigerant used in the system to lubricate
O-rings during the assembly process.
(3) Connect the liquid refrigerant line on the evap-
orator.
(4) Install the secondary locking clip on the liquid
line(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT
LINE
COUPLER
-
INSTALLATION).
(5) Install the EGR solenoid and mounting bracket
on the coolant bottle.
(6) Connect the liquid line coupler. Torque to 33
N·m (25 ft. lbs.).
(7) Engage the refrigerant line in its mounting clips.
(8) Connect the horn electrical.
(9) Connect the liquid line on the condenser(Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
REFRIGERANT LINE COUPLER - INSTALLATION).
(10) Install the secondary locking clip on the liquid
line.
(11) Install the air filter assembly in the vehicle.
(12) Evacuate and Charge the refrigerant system(Re-
fer to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/REFRIGERANT - STANDARD PROCEDURE) and
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT
-
STANDARD
PROCE-
DURE).
(13) Connect the negative battery cable.
(14) Check the liquid line and connections for any
refrigerant leaks.
Fig. 1 2.5L Diesel Liquid Line Coupler Location
1 - LIQUID LINE COUPLER
2 - LIQUID LINE
R1
LIQUID LINE
24a - 13
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