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1991 Jeep Comanche A/C replacement & r134 conversion

csprof on Mon February 23, 2009 10:52 AM User is offline

Year: 1991
Make: Jeep
Model: Comanche Eliminator
Engine Size: 4.0L
Refrigerant Type: None, currently
Country of Origin: United States

I'm new this forum and new to A/C systems, but I'm an experienced mechanic.

I have been overhauling this vehicle which came to me with a trashed and open A/C system. It's evaporator and expansion valve have apparently been modified from stock as a result of past repairs.

My intention is to replace all the A/C components and convert it to R-134a in the process. As the 1994-1996 Jeep XJ was converted by Jeep to R-134a, I am expecting to use the components for that system to install in my 1991 Comanche. The form and fit should work for the evaporator, condenser and compressor, and I hope, for the accumulator as well.

As I don't have a 94-96 Jeep to look at, I have some questions about the differences:

1) Does the 94-96 XJ A/C use an expansion block or an orifice tube? If its an orifice tube, where is it located? At the evaporator?

2) The 94-96 XJ presumably has a HPCO switch. Where would this switch normally be located?

3) I suspect that the stock OE type condenser for 94-96 XJ is marginal for R-134a, is there an upgraded condenser I should consider with the same form and fit?

4) Are there pitfalls to what I am doing that I may not be aware of?

After I get things together, I plan to evacuate the system and take it to a shop for charging and oil.

Thank You,

JACK ADAMS on Mon February 23, 2009 3:29 PM User is offline

You will be able to use the OEM evaporator for the conversion and any hard lines. You will need to have all hoses rebuilt with barrier hoses, change the drier, expansion valve, add a HPCS (High Pressure Cut-out Switch) and for best results use a PFC (Parallel Flow Condenser). Now with a PFC you will have to have the hoses built to fit, as they will not be the same as OEM design.

To answer to your Questions,

1) Does the 94-96 XJ A/C use an expansion block or an orifice tube? If its an orifice tube, where is it located? At the evaporator? This system still used a TXV at the evaporator.

2) The 94-96 XJ presumably has a HPCO switch. Where would this switch normally be located? This system has a switch on the drier.

3) I suspect that the stock OE type condenser for 94-96 XJ is marginal for R-134a, is there an upgraded condenser I should consider with the same form and fit? Not totally sure on the fit but most OEM 134a systems used metric fittings so the parts can not be used from one another. Darn those OEM guys!

4) Are there pitfalls to what I am doing that I may not be aware of? No as long as you do the job correct the first time.


Hope this helps and good luck!

TRB on Mon February 23, 2009 8:48 PM User is offlineView users profile

Nice reply Jack!

The condenser we use which requires custom mounting & hoses is a 12-0632A. This only will work in the 4.0L vehicles.

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Edited: Mon February 23, 2009 at 8:49 PM by TRB

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