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Old 08-28-2013, 09:00 AM   #1
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2004 TJ air conditioner vacuum leak?

My A/C will only blow through the defrost and floor vents. This has been a progressive problem. When it started it blew through the defrost/floor vents only when I was driving on the highway and through the dash vents when I was stopped or going slow. Now it's through the defrost/floor vents all the time. I read some older posts about this problem and the consensus seemed to be that it was a vacuum leak somewhere. I've looked under the dash on the drivers side and behind the glove box on the passenger side. All the vacuum lines seem to be in proper working order (connected properly, not cracked or dry rotted, etc.). Although I could only trace 4 of the 6 lines. I then looked under the hood. Assuming I'm looking at the correct lines, I traced them from the intake manifold to the vacuum reservoir. All the boots appear to be seated correctly and not cracked. All the lines appear to be firmly in the boots and not pinched anywhere. I did notice, however, that the boot that connects the vacuum line to the manifold is real loose (where #2 connects to #5 in the below picture). It takes almost no effort to pull it off.

So the questions are: is that the problem? Could it be a check valve? If not, what else could it be or where else can I look? Is there a way, other than visual inspection, to see if there is a leak somewhere?

Thanks for your time.









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Old 08-28-2013, 09:18 AM   #2
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Double check the line at the reservoir under the battery for cracks. Easy way to see it is lay under the Jeep behind the right front tire an look up.

As far as the loose elbow, it might be leaking enough but that one usually just falls off, you can take a zip tie and wrap it around there to tighten it up.

If you smoke or know someone who does you could undo the elbow and have them blow smoke through the line then watch for any leaks
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Old 08-28-2013, 09:29 AM   #3
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I tried to look under the passenger side wheel well and I didn't see a line like that. On mine, the line follows the firewall, routes behind the battery then under the battery tray. I removed both last night and found where mice had been slumbering throughout the winter.
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Old 08-28-2013, 09:30 AM   #4
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also inspect that line #4 in the photo. That is where mine was leaking causing the exact same problem you describe. There are a couple points where the line can rub against metal and rub a very small hole in it. In my case it was right behind the brake booster.
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Old 08-28-2013, 09:39 AM   #5
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With the engine running , can I spray something like WD-40 on the line to help locate a small hole?
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Old 08-28-2013, 09:56 AM   #6
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Quote:
Originally Posted by MinnesotaJeep View Post
With the engine running , can I spray something like WD-40 on the line to help locate a small hole?
I doubt WD-40 will work, but carb cleaner or ether will do the job.
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Old 08-29-2013, 09:31 AM   #7
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After trip to my local AutoZone and purchasing/installing the 90° rubber boot that fits over the fitting on the intake manifold, the A/C still didn't work. Then after a trip to Napa and purchasing/installing a blower motor resistor, the A/C still didn’t work (do these guys really know what they’re talking about?). As I was checking the check valves, I found the problem. The vacuum line the goes through the firewall had a big hole in it on the outside of the bend. I wrapped it with black electrical tape and it works fine now. I also rerouted the line. Originally it ran in between the wire loom and the heater hose. It was probably rubbing on that hose clamp. I moved it to the other side of wire loom and added a zip tie to keep it up and out of the way.
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Old 08-29-2013, 10:07 AM   #8
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Quote:
Originally Posted by MinnesotaJeep View Post
After trip to my local AutoZone and purchasing/installing the 90° rubber boot that fits over the fitting on the intake manifold, the A/C still didn't work. Then after a trip to Napa and purchasing/installing a blower motor resistor, the A/C still didn’t work (do these guys really know what they’re talking about?). As I was checking the check valves, I found the problem. The vacuum line the goes through the firewall had a big hole in it on the outside of the bend. I wrapped it with black electrical tape and it works fine now. I also rerouted the line. Originally it ran in between the wire loom and the heater hose. It was probably rubbing on that hose clamp. I moved it to the other side of wire loom and added a zip tie to keep it up and out of the way.
Blower motor resistor only controls the fan speed. Not sure why you replaced that. We were pointing you towards the vacuum system because that is the problem 99.99% of the time (probably 100%). Regardless, glad you got it fixed
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Old 08-29-2013, 10:25 AM   #9
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The dude at Napa suggested the resistor. Even after I explained everything that I had researched, he still stuck with the resistor. Just goes to show ya.
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Old 08-29-2013, 10:30 AM   #10
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Quote:
Originally Posted by MinnesotaJeep View Post
After trip to my local AutoZone and purchasing/installing the 90° rubber boot that fits over the fitting on the intake manifold, the A/C still didn't work. Then after a trip to Napa and purchasing/installing a blower motor resistor, the A/C still didn’t work (do these guys really know what they’re talking about?). As I was checking the check valves, I found the problem. The vacuum line the goes through the firewall had a big hole in it on the outside of the bend. I wrapped it with black electrical tape and it works fine now. I also rerouted the line. Originally it ran in between the wire loom and the heater hose. It was probably rubbing on that hose clamp. I moved it to the other side of wire loom and added a zip tie to keep it up and out of the way.
That must be a common spot for them to break. Mine broke right where yours did. It took me a while to find it, but I was really happy it wasn't something more serious.

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