Before and after, replacing the condenser (and dryer). The old dryer had been bent by the previous owner in a minor fender bender, but I didn't want to risk a full recharge with the bent lines on the dryer, and the condenser comes attached.

I ended up finding the leak in the system as I was replacing the condenser, which turned out to be a crack in the end of the high pressure line (right at the connector into the condenser). I wouldn't have found the leak unless I replaced the condenser, as it is hidden behind the connector cover. I also replaced the high pressure switch at the same time. The new high pressure line came a little bent, but shaped right into the form of the old line, by hand. The old line came out fairly easily, with just removing the radiator overflow tank, and tilting the radiator back towards the cabin a little.

The thermister sensor can be tested with a multimeter, with the dial set to ohms, unplug the connector attached to the air filter box under the glove box, and probe the sensor side of the connector. You should get a reading of 4.5 (on the 20k ohm setting). My old one was reading 4.17, so I think that was also on it's way out, and I know these sensors are popular for going bad.

After replacing all the above items which fixed the leak issue, the A/C compressor was still not engaging. With the ignition in the run position, I was unable to get continuity between the blue/yellow wire of the high pressure switch, and bypassing it by jumping the connector also did nothing. I had trouble tracing the wires with the Haynes manual, because the A/C system was changed up mid-2003 with fewer wires, but ended figuring out that the ground goes through the A/C switch in the center console and out to the high pressure switch. The connector in the back of the air temp/speed board had just barely wiggled out (see above picture), not enough for the A/C light to stop working, but enough for the ground to no longer complete the circuit to the pressure switch.

The complete list of items used in this project, and other projects, can be found in the Parts List below.