1992 XJ A/C Air Conditioning Replacement - Parts List

[mhead]

1992 4-door Jeep Cherokee XJ with 4.0 6 cyl engine and AW-4 auto trans.
Date of purchases 2023AUG

Userful reference thread
https://www.naxja.org/forum/showthread.php?t=1100177&highlight=air+conditioning

The project goal was to replace all A/C parts, except the evaporator, with new and to convert system from R-12 to R-134a refrigerant. The project took several months with various shipping delays and incorrect parts orders. The list here in this post should shorten the overall time dramatically.

I used Youtube extensively to learn how to install and charge. Prices are what I paid not including shipping. The total project ran about $800 but now I have the tools for future use.

Refrigerant flow in this system is... compressor, discharge hose, condensor, liquid hose, receiver-dryer, liquid hose, expansion valve, evaporator, suction hose, compressor. There is a pressure switch on the receiver-dryer.

I was able to purchase all replacement parts except the liquid hoses. These I constructed myself since I could not find a local shop willing to do this task.

All replacement parts were drop-in matches for existing parts. No special mounting or other efforts were required.

The original receiver-dryer supplied in the Parts Geek kit uses an obsolete fitting so a replacement receiver-drier must be purchased. The replacement uses standard #6 fittings.

Jeep repair threads encourage the use of a PARALLEL type condensor. I found and purchased condensers that were described as PARALLEL. All were in fact series (serpentine) and all were returned. In the end I simply used the series condensor that was supplied with the Parts Geek kit.

The condensor in the Parts Geek kit arrives with short tubes that route refrigerant around the side of the radiator. I removed and discarded the short discharge tube since the Parts Geek discharge hose also has routing around the side of the radiator.

The original compressor and the Parts Geek kit replacement compressor were identical and are Sanden International SD-709. I replaced the original valves on the back of the compressor with R-134a fittings.

Since R-134a refrigerant uses a different compressor oil, the evaporator must be flushed. I flushed the evaporator. The flushing agent dries slowly. After flushing I arranged a fan and funnel to blow air as best I could through the evaporator. After several days, blasts of compressed air into the evaporator no longer caused it to cough up liquid flusing agent.


Original compressor had a tag showing charge of R-12 of 2.38 pounds. R-134a is lighter and so less R-134a refrigerant is required. Several internet sources give this formula for conversion

R134a charge (pounds) = (0.9 * R12 charge (pounds)) - 0.25 (pounds)

So R-134a charge is 1.9 pounds or 30 ounces.

Jeep FSM states 135 ml oil should be in the system. Besides the compressor the remaining system is all new or flushed so no oil is in the system. Compressor arrived with a tag stating 180 ml of oil (PAG for R-134a) was already in the compressor. I drained and discarded 45 ml oil, leaving the required 135 ml oil within the compressor. I next drained about 50 ml oil from compressor and poured this into the condenser to initially distribute oil in the system.

I vac'ed the entire system for more than an hour on multiple days. After several days I checked the system to be sure that it held vac.

I purchased 3 X 12 oz cans of R-134a. Charging the system went well and is described by several Youtube videos. I put two cans completely into the system. I weighed the last can, then filled the system until weight was reduced by 6 oz, giving 30 oz total charge.

Be sure to CAREFULLY, with magnifiers, inspect every seal prior to joining. I found a leak in a Schrader valve due to a bit of metal, bits of cardboard in refrigerant can openings, poorly manufactured seals on receiver-dryer, and various bits of metal in bad places. No one is watching the manufacture of these parts.

Prices do not include various mistakes I made in ordering incorrect parts. Mistakes added about $100. I could have been more cost efficient with tools and should perhaps have ordered the Parts Geek kit if I had known the part numbers of included items...

Cold Hose and Jeep Air are in fact the same company. Perhaps they will consolidate orders for the purposes of saving on shipping.

SUMMARY


Special Tools & Equipment

Lichamp R134a Can Tap $10.79
https://www.amazon.com/dp/B0B33CDLF3?psc=1&ref=ppx_yo2ov_dt_b_product_details

Aupoko R12 R22 to R134a Adapter fittings $8.99
https://www.amazon.com/dp/B07PXJYB3C?psc=1&ref=ppx_yo2ov_dt_b_product_details

Foifatt AC Flush Kit $31.99
https://www.amazon.com/dp/B094QQTQ51?psc=1&ref=ppx_yo2ov_dt_b_product_details

AMZCNC 71500 Hydraulic A/C Hose Crimper $129.88
https://www.amazon.com/your-orders/...rtIndex=20&ref_=ppx_yo2ov_dt_b_pagination_2_3

OMT AC Gauge Set $35.99
https://www.amazon.com/Orion-Motor-...-2-spons&sp_csd=d2lkZ2V0TmFtZT1zcF9hdGY&psc=1

Vacuum pump (I already had this) $70

Total Special Tools & Equipment $288

Materials

FLUSHING AGENT
TSI Supercool FFQ High-Temp A/C Flush $17.95
https://www.amazon.com/dp/B00CFQQX5S?psc=1&ref=ppx_yo2ov_dt_b_product_details

REFRIGERANT
Chemours R134a Refirgerant $33.49
https://www.amazon.com/dp/B088HGRJ3Z?psc=1&ref=ppx_yo2ov_dt_b_product_details

Total Materials $51

Replacement Parts

COMPRESSOR, CONDENSER, EXPANSION VALVE
UAC A/C Compressor Kit $272.43
Parts Geek 2227-05980682

https://www.partsgeek.com/catalog/1...fs-c_compressor.html?rp=a-fs-c_compressor_kit

Compressor UAC SD7H15 CO7701C in this kit is identical to compressor in my Jeep. Both are Sanden International SD-709

Did NOT use Receiver-Dryer or PAG oil supplied in this kit.

Condenser UAC CN 4174PFC SX 2203UL
Expansion Valve UAC EX 9448C

RECEIVER-DRYER
Cold Hose Cherokee R134a Drier 22-8264 $29.99

PRESSURE SWITCH
Cold Hose 10mm Female Binary Switch 11909886 $19.99
Santech MT1366

VAPOR HOSES
Four Seasons A/C Refrigerant Discharge Hose 56279 $47.43
Parts Geek 2227-05318138
https://www.partsgeek.com/catalog/1992/jeep/cherokee/climate_control/a-fs-c_hose.html

Four Seasons A/C Refrigerant Suction Hose 56278 $38.43
Parts Geek 2227-05318137

LIQUID HOSES
Construction of Condenser to Receiver-Dryer liquid hose:
Cold Hose #6 (5/16") Standard Barrier A/C Hose, 9", BH6 $3
Cold Hose Custom 90 degree fitting $60
(two 90 degrees S seperated by 5" – see the original in your vehicle)
Cold hose #6 Straight O-ring Fitting BL1301 $6.72
Total 69.72

Construction of Receiver-Dryer to Expansion Valve hose:
Cold Hose #6 (5/16") Standard Barrier A/C Hose, 16", BH6 $5
Cold Hose #6 90 degree O-ring Fitting BL1321 $6.57
Cold Hose #6 Straight O-ring Fitting BL1401 $6.72
Total 39.57


MISC FITTINGS REQUIRED
R134-a Fittings for compressor
Jeep Air Tube-O Compressor Suctin & Discharge Fittings with R-134a Ports $26.99
FT0168-FT0169
https://jeepair.com/collections/fit...ings-with-r-134a-ports?variant=32066979561557

Total parts: $523

 

[Anak]

Very nicely done.

Bummer that hoses cannot be purchased anymore. I should probably start grabbing some of those from the JY in the future, just for the sake of the ends.

I will be forwarding a link to Varmint #1 who is attempting to convert his '92 over to R134a. His project is somewhat the opposite of yours. He replaced his evaporator along with his leaking heater core and hopes to avoid replacing his compressor or condenser.

 

[mhead]

"Bummer that hoses cannot be purchased anymore. I should probably start grabbing some of those from the JY in the future, just for the sake of the ends."

Hose ends are crimped and can't be removed from the rubber hose. My hoses were 32 years old. I put a new engine in recently and in the process of moving my A/C compressor a hose must have cracked which let all my R-12 escape. Anyway after the new engine was in the A/C pressure was gone.

Moral of this story is that the old rubber hoses can not be trusted. The good news is that replacements can be made at small expense, especially if you can borrow the crimper tool and if you use rubber hose to implement the custom fitting having the S curve.

I should mention that the original receiver-dryer has a non-standard fitting that persons at Cool Hose said was no longer available. Cool Hose sold me a replacement receiver-dryer with standard fittings. They also offered to repair my original fitting if I would send my original to them. I do not recall what $ Cool Hose wanted to repair my fitting but it wasn't cheap. The replacement receiver-dryer was $30 which seemed the best choice.

 

[mhead]

With regard to Varmint #1... unfortunately the oil used with original R-12 is not compatible with R-134a. So the old oil has to go. Internet says expansion valve and receiver-dryer simply MUST be replaced. This leaves hoses, compressor, and condenser for cleaning. Yes, parts can be cleaned, but this involves expense and work with uncertain result. A clean condenser will have a second life but compressor is worn, and hoses are very unreliable - not worth cleaning.

Swapping an evaporator is a lot of work. The remainder of a complete swap is mostly just money.

 

[Anak]

Swapping an evaporator is a lot of work. The remainder of a complete swap is mostly just money.

Keep in mind, he is a full time college student. He doesn't have money. He can put in labor during breaks.

 

[mhead]

College? I remember those days but a while back for me.

Something I forgot to mention is that Cool Hose will fabricate the hose. This was not an option for me since I did not have a hose design and did not know exactly the fittings. I posted this same info at another jeep forum. This forum allows me to upload a picture which I did of the liquid hoses. The picture is descriptive enough to describe what is needed to Cool Hose. URL is

https://www.jeepforum.com/threads/1...eplacement-r-12-to-r-134a-conversion.4478866/

 

[cruiser54]

I don't mean to burst anyone's bubble.

This info is helpful as a resource.

But I must point out that all that was done was not necessary to convert from R12 to R134a.

There are other options that are WAAAAAY less expensive labor and parts-wise and just as effective.

We've done it many times over the years.

 

[Rob Mayercik]

Well, shoot. I typed out a big long response and apparently never went past the preview.

Anyhow, I'm with Cruiser - in many cases it's not necessary to replace as much as the O/P did - with my 92, I had the conversion done when I had to replace a rotted condenser. Besides that, I think they only did the adapter fittings and receiver/dryer (was more than 15 years ago, so not 100% certain). Since then, other than another condenser (salt belt), I've only replaced the "liquid line" and that was due to it being 27 years old and rusted out. Always seems to blow as cold with R-134A as it did on R-12, far as I can tell.

That being said, the O/P did say he intended to do a full system replace, and since he didn't mention how long the system in his truck had been inoperative, who can say what shape any of the parts were still in? My 84 Dodge's A/C last functioned in the mid 90s (did the two main hoses, and then 4 weeks later the condenser failed); I don't know that I'd trust anything in the system to hold up more than about 30 seconds under pressure or vacuum after all this time with the system not sealed...

 

[SprobbyBlongo]

Ive been going through the same thing and just found this thread. Why did you choose to switch to the new style drier? The fittings on the condenser and expansion valve are the same on the 92 and 94, so why build new liquid lines and go through all the trouble? Is there anything wrong with just flushing the old liquid lines instead of replacing them, and still replacing the rest of the components?

 

[mhead]

My goal was to replace the entire AC system for the joy of new parts and without worrying about cost. I succeeded except for the evaporator which, due to its location under the dash, was just too much work. I used the new style dryer because it was new. I believe that other XJ owners flush the system and reuse parts. Watchout...the oil used with R12 refrigerant is NOT compatible with the replacement refrigerant and what's worse is that there is some bad chemistry if they mix. I do not know how well the system must be flushed or how to tell when it is flushed enough. Some of the other people who replied to this thread may have advice. As for the hoses...these rubber parts were 32 years old and I judged them to have served me well but their time was come for replacement. I placed this thread not so much to recommend but rather to provide an up to date parts list for people with the same goal. If getting cold air from the AC is the goal there are less expensive ways.

 

[SprobbyBlongo]

My goal was to replace the entire AC system for the joy of new parts and without worrying about cost. I succeeded except for the evaporator which, due to its location under the dash, was just too much work. I used the new style dryer because it was new. I believe that other XJ owners flush the system and reuse parts. Watchout...the oil used with R12 refrigerant is NOT compatible with the replacement refrigerant and what's worse is that there is some bad chemistry if they mix. I do not know how well the system must be flushed or how to tell when it is flushed enough. Some of the other people who replied to this thread may have advice. As for the hoses...these rubber parts were 32 years old and I judged them to have served me well but their time was come for replacement. I placed this thread not so much to recommend but rather to provide an up to date parts list for people with the same goal. If getting cold air from the AC is the goal there are less expensive ways.

I reached out to cold hose about making those two liquid lines for me, and included your picture from jeep forums, and they replied with the following:

"We would need to confirm the dimensions of that custom formed 90 degree fitting. Do you have a name for the customer who referred you? If their order is recent we might be able to pull up the specifications we built it to.
Your photo only shows one #6 hose. We can still build the other one as it has both in stock fittings. Is the effective rubber length 16" or is that the overall length?"

"We currently make this kit for the liquid line that connects to the drier to the expansion valve: https://jeepair.com/products/copy-o...connect-eliminator-kit?variant=42041565315269
If you are using the 95 drier which is shown in the above link we can sell you the hose separately"

Any chance you could dm me your name or an order number or something they could identify your order with? Also, to me it looks like you included both liquid lines in the picture but correct me if im wrong, is there something im missing?

Thanks.

 

[SprobbyBlongo]

I reached out to cold hose about making those two liquid lines for me, and included your picture from jeep forums, and they replied with the following:

"We would need to confirm the dimensions of that custom formed 90 degree fitting. Do you have a name for the customer who referred you? If their order is recent we might be able to pull up the specifications we built it to.
Your photo only shows one #6 hose. We can still build the other one as it has both in stock fittings. Is the effective rubber length 16" or is that the overall length?"

"We currently make this kit for the liquid line that connects to the drier to the expansion valve: https://jeepair.com/products/copy-o...connect-eliminator-kit?variant=42041565315269
If you are using the 95 drier which is shown in the above link we can sell you the hose separately"

Any chance you could dm me your name or an order number or something they could identify your order with? Also, to me it looks like you included both liquid lines in the picture but correct me if im wrong, is there something im missing?

Thanks.

Also:

I found his order but unfortunately since it was in 2023 we no longer have the drawing. We can provide you with the 3 fittings and hose, we would just need more information on that custom 90 degree

 

[SprobbyBlongo]

Since that jeep air kit has the new liquid line from the drier to the expansion valve, can we replace the other liquid line with an aftermarket one intended for a 94-96? Like this: FOUR SEASONS 56831

 

[mhead]

I can review my records and perhaps find the drawing but not for the next 3 days. I can reply over the weekend. Also, I considered having the hoses custom made but chose to do them myself since the cost difference was small and I would end up owning the tool.

 

[SprobbyBlongo]

I can review my records and perhaps find the drawing but not for the next 3 days. I can reply over the weekend. Also, I considered having the hoses custom made but chose to do them myself since the cost difference was small and I would end up owning the tool.

I'm thinking custom lines aren't necessary at all now that JeepAir has that kit. I am still waiting on some parts, but I will come back here to say how it turned out. I plan on flushing the original pipe assembly on the original condenser and reusing it if I need it, as a new one isnt included with the spectra condenser. The UAC condenser and a few others appear to have them included.

RockAuto says SP-15 Oil for the compressor but the sticker on the compressor says PAG 46. I called denso tech support and left a message asking for clarification, ill post their response when I can.

Wish me luck

Compressor - DENSO 4717005 - $153.79
Compressor Ports - JEEPAIR FT0205-FT0206 - $26.99
Condenser - SPECTRA PREMIUM 74173 - $61.79
Drier Kit - JEEPAIR CK-9193EK - $99.99
Discharge Line - FOUR SEASONS 56279 - $42.79
Liquid Line - FOUR SEASONS 56831 - $42.79
Suction Line - FOUR SEASONS 56278 - $31.88
Expansion Valve - FOUR SEASONS 38880 - $18.95
O-Rings - FOUR SEASONS 26758 - $6.17

 

[mhead]

I'm thinking custom lines aren't necessary at all now that JeepAir has that kit. I am still waiting on some parts, but I will come back here to say how it turned out. I plan on flushing the original pipe assembly on the original condenser and reusing it if I need it, as a new one isnt included with the spectra condenser. The UAC condenser and a few others appear to have them included.

RockAuto says SP-15 Oil for the compressor but the sticker on the compressor says PAG 46. I called denso tech support and left a message asking for clarification, ill post their response when I can.

Wish me luck

Compressor - DENSO 4717005 - $153.79
Compressor Ports - JEEPAIR FT0205-FT0206 - $26.99
Condenser - SPECTRA PREMIUM 74173 - $61.79
Drier Kit - JEEPAIR CK-9193EK - $99.99
Discharge Line - FOUR SEASONS 56279 - $42.79
Liquid Line - FOUR SEASONS 56831 - $42.79
Suction Line - FOUR SEASONS 56278 - $31.88
Expansion Valve - FOUR SEASONS 38880 - $18.95
O-Rings - FOUR SEASONS 26758 - $6.17

Great! Thanks for posting your bill of materials and part numbers. Since you seem to be going, I won't hunt for my drawing for the S-fitting. Tell me if you need it in the future.