WARNING: The A/C system contains refrigerant
under high pressure. Repairs should only be per-
formed by qualified service personnel. Severe per-
sonal injury or death may result from improper
service procedures.

WARNING: Avoid breathing the refrigerant and
refrigerant oil vapor or mist. Exposure may irritate
the eyes, nose, and/or throat. Wear eye protection
when servicing the A/C refrigerant system. Serious
eye injury can result from direct contact with the
refrigerant. If eye contact occurs, seek medical
attention immediately.

WARNING: Do not expose the refrigerant to open
flame. Poisonous gas is created when refrigerant is
burned. An electronic leak detector is recom-
mended. Severe personal injury or death may result
from improper service procedures.

WARNING: If accidental system discharge occurs,
ventilate the work area before resuming service.
Large amounts of refrigerant released in a closed
work area will displace the oxygen and cause suf-
focation and death.

WARNING: The evaporation rate of R-134a refriger-
ant at average temperature and altitude is extremely
high. As a result, anything that comes in contact
with the refrigerant will freeze. Always protect the
skin or delicate objects from direct contact with the
refrigerant.

WARNING: The R-134a service equipment or the
vehicle refrigerant system should not be pressure
tested or leak tested with compressed air. Some
mixtures of air and R-134a have been shown to be
combustible at elevated pressures. These mixtures
are potentially dangerous, and may result in fire or
explosion causing property damage, personal injury
or death.

WARNING: The engine cooling system is designed
to develop internal pressures of 97 to 123 kilopas-
cals (14 to 18 pounds per square inch). Do not
remove or loosen the coolant pressure cap, cylin-
der block drain plugs, radiator drain, radiator
hoses, heater hoses, or hose clamps while the

engine cooling system is hot and under pressure.
Allow the vehicle to cool for a minimum of 15 min-
utes before opening the cooling system for service.
Failure to observe this warning can result in seri-
ous burns from the heated engine coolant.

CAUTIONS

CAUTION: Never add R-12 to a refrigerant system
designed to use R-134a. Do not use R-12 equipment
or parts on a R-134a A/C system. These refrigerants
are not compatible and damage to the A/C system
will result.

CAUTION: Never use R-12 refrigerant oil in a A/C
system designed to use R-134a refrigerant oil.
These refrigerant oils are not compatible and dam-
age to the A/C system will result.

CAUTION: The use of A/C system sealers may
result in damage to A/C refrigerant recovery/evacu-
ation/recharging

equipment

and/or A/C

system.

Many federal, state/provincial and local regulations
prohibit the recharge of A/C systems with known
leaks. DaimlerChrysler recommends the detection
of A/C system leaks through the use of approved
leak detectors and fluorescent leak detection dyes.
Vehicles found with A/C system sealers should be
treated as contaminated and replacement of the
entire A/C refrigerant system is recommended. A/C
systems found to be contaminated with A/C system
sealers, A/C stop-leak products or seal conditioners
voids the warranty for the A/C system.

CAUTION: Recover the refrigerant before opening
any fitting or connection. Open the fittings with
caution, even after the system has been dis-
charged. Never open or loosen a connection before
recovering the refrigerant.

CAUTION: If equipped, do not remove the second-
ary retention clip from any spring-lock coupler con-
nection

while

the

refrigerant

system

under

pressure. Recover the refrigerant before removing
the secondary retention clip. Open the fittings with
caution, even after the system has been dis-
charged. Never open or loosen a connection before
recovering the refrigerant.

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24 - 37

CAUTION: The internal parts of the A/C system will
remain stable as long as moisture-free refrigerant
and refrigerant oil is used. Abnormal amounts of
dirt, moisture or air can upset the chemical stability.
This may cause operational troubles or even seri-
ous damage if present in more than very small
quantities.

Before

disconnecting

component,

clean the outside of the fittings thoroughly to pre-
vent contamination from entering the refrigerant
system. Keep service tools and the work area clean.
Do not open the refrigerant system or uncap a
replacement component until you are ready to ser-
vice the system. Immediately after disconnecting a
component from the refrigerant system, seal the
open fittings with a cap or plug. This will prevent
contamination from entering the A/C system.

CAUTION: Refrigerant oil will absorb moisture from
the atmosphere if left uncapped. Do not open a
container of refrigerant oil until you are ready to
use it. Replace the cap on the oil container immedi-
ately after using. Store refrigerant oil only in a
clean, airtight, and moisture-free container.

CAUTION: Do not overcharge the refrigerant sys-
tem. Overcharging will cause excessive compressor
head pressure and can cause compressor noise
and A/C system failure.

DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS

WARNING: R-134a SERVICE EQUIPMENT OR VEHI-
CLE A/C SYSTEM SHOULD NOT BE PRESSURE
TESTED OR LEAK TESTED WITH COMPRESSED
AIR. MIXTURE OF AIR and R-134a CAN BE COM-
BUSTIBLE AT ELEVATED PRESSURES. THESE MIX-
TURES ARE POTENTIALLY DANGEROUS AND MAY
RESULT IN FIRE OR EXPLOSION CAUSING INJURY
OR PROPERTY DAMAGE.
AVOID BREATHING A/C REFRIGERANT AND LUBRI-
CANT VAPOR OR MIST. EXPOSURE MAY IRRITATE
EYES, NOSE AND THROAT. USE ONLY APPROVED
SERVICE EQUIPMENT MEETING SAE REQUIRE-
MENTS TO DISCHARGE R-134a SYSTEM. IF ACCI-
DENTAL

SYSTEM

DISCHARGE

OCCURS,

VENTILATE WORK AREA BEFORE RESUMING SER-
VICE.

NOTE: The refrigerant system does come from the
factory with a yellow tracer dye already installed to
aid in detection of leaks.

If the A/C system is not cooling properly, determine

if the refrigerant system is fully charged with
R-134a. This is accomplished by performing a system
Charge Level-Check or Fill. If while performing this
test A/C liquid line pressure is less than 345 kPa (50
psi) proceed to System Empty procedure. If liquid
line pressure is greater than 345 kPa (50 psi) proceed
to System Low procedure. If the refrigerant system is
empty or low in refrigerant charge, a leak at any line
fitting or component seal is likely. A review of the fit-
tings, lines and components for oily residue is an
indication of the leak location. To detect a leak in the
refrigerant system, perform one of the following pro-
cedures as indicated by the symptoms.

SYSTEM EMPTY

(1) Evacuate the refrigerant system to the lowest

degree of vacuum possible (approx. 28 in Hg.). Deter-
mine if the system holds a vacuum for 15 minutes. If
vacuum is held, a leak is probably not present. If sys-
tem will not maintain vacuum level, proceed with
this procedure.

(2) Prepare a 0.284 Kg. (10 oz.) refrigerant charge

to be injected into the system.

(3) Connect and dispense 0.284 Kg. (10 oz.) of

refrigerant into the evacuated refrigerant system.

(4) Proceed to Step 2 of System Low procedure.

SYSTEM LOW

(1) Determine if there is any (R-134a) refrigerant

in the system.

(2) Position the vehicle in a wind free work area.

This will aid in detecting small leaks.

(3) Bring the refrigerant system up to operating

temperature and pressure. This is done by allowing
the engine to run for five minutes with the system
set to the following:

• Transaxle in Park or Neutral with parking

brake set

• Engine idling at 700 rpm

• A/C controls set in 100 percent outside air

• Blower switch in the high A/C position

• A/C in the ON position

• Open all windows

CAUTION: A leak detector designed for R-12 refrig-
erant (only) will not detect leaks in a R-134a refrig-
erant system.

(4) Shut off the vehicle and wait 2 to 7 minutes.

Then use an Electronic Leak Detector that is
designed to detect R-134a type refrigerant and search
for leaks. Fittings, lines, or components that appear
to be oily usually indicates a refrigerant leak. To
inspect the evaporator core for leaks, insert the leak
detector probe into the drain tube opening or a heat
duct. A R-134a dye is available to aid in leak detec-

24 - 38

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tion, use only DaimlerChrysler approved refrigerant
dye.

STANDARD PROCEDURE

REFRIGERANT SYSTEM SERVICE EQUIPMENT

WARNING: Eye protection must be worn when ser-
vicing an air conditioning refrigerant system. Turn
off (rotate clockwise) all valves on the equipment
being used, before connecting to or disconnecting
from the refrigerant system. Failure to observe
these warnings may result in personal injury or
death.

WARNING: Review the warnings and cautions in the
front of this section before performing the following
operation (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING - A/C SYSTEM) and
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - CAUTION - A/C SYSTEM).

When servicing the A/C system, a R-134a refriger-

ant recovery/recycling/charging station that meets
SAE Standard J2210 must be used (Fig. 1). Contact
an automotive service equipment supplier for refrig-
erant recovery/recycling/charging equipment. Refer to
the operating instructions supplied by the equipment
manufacturer for proper care and use of this equip-
ment.

A manifold gauge set may be needed with some

recovery/recycling/charging equipment (Fig. 2). 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 low side
service port. On 2.0L LHD models, this port is
located on the liquid line near the accumulator. On
2.4L and RHD models, this port is located on the suc-
tion line.

HIGH PRESSURE GAUGE HOSE The high pres-

sure hose (Red with Black stripe) attaches to the
high side service port. On 2.0L LHD models, this
port is located on the discharge line fitting at the
condenser. On 2.4L and RHD models, this port is
located on the liquid line fitting at the receiver/drier.

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.

Fig. 1 Refrigerant Recovery/Recycling Station -

Typical

1 - R-134 REFRIGERANT STATION

Fig. 2 Manifold Gauge Set - Typical

1 - HIGH PRESSURE GAUGE
2 - VALVE
3 - VACUUM/REFRIGERANT HOSE (YELLOW W/ BLACK STRIPE)
4 - HIGH PRESSURE HOSE (RED W/ BLACK STRIPE)
5 - LOW PRESSURE HOSE (BLUE W/ BLACK STRIPE)
6 - VALVE
7 - LOW PRESSURE GAUGE

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