tow DODGE RAM 1999 Service Repair Manual
Page 12 of 1691
A/C C O M PR ESSO R R EFR IG ER AN T O IL C HEC KIN G
1999 D odge P ic ku p R 1500
1999 GENERAL SERVICING
A/C Compressor Refrigerant Oil Checking
All Models
* PLEASE READ THIS FIRST *
NOTE: For compressor applications, see COMPRESSOR APPLICATIONS &
BODY DESIGNATIONS. DO NOT exceed A/C system refrigerant oil
capacity when servicing system. See CAPACITIES.
BODY DESIGNATIONS
BODY DESIGNATIONS (CHRYSLER CORP. CARS) \
\
\
\
\
\
\
Model ( 1) Body Designation
Avenger & Sebring Coupe ................................ "FJ22" Body
Breeze, Cirrus & Stratus ................................. "JA" Body
Concorde, Intrepid, LHS & 300M ........................... "LH" Body
Neon ..................................................... "PL" Body
Sebring Convertible ...................................... "JX" Body
( 1) - Body codes are determined by fifth character of VIN code.
\
\
\
\
\
\
\
BODY DESIGNATIONS (CHRYSLER CORP. LIGHT TRUCKS & VANS) \
\
\
\
\
\
\
Model Body Designation
Caravan, Town & Country, & Voyager ..................... "NS" Series
Dakota ................................................. "AN" Series
Durango ................................................ "DN" Series
Ram Pickup .......................................... "BR/BE" Series
Ram Van/Wagon .......................................... "AB" Series
\
\
\
\
\
\
\
BODY DESIGNATIONS (FORD MOTOR CO. LIGHT TRUCKS & VANS) \
\
\
\
\
\
\
Model Body Designation
Explorer & Mountaineer .................................. "U" Series
Pickup .................................................. "F" Series
Ranger .................................................. "R" Series
Van ..................................................... "E" Series
\
\
\
\
\
\
\
BODY DESIGNATIONS (GENERAL MOTORS CARS) \
\
\
\
\
\
\
Model ( 1) Body Designation
Alero, Cutlass, Grand Am & Malibu ......................... "N" Body
Aurora & Riviera .......................................... "G" Body
Bonneville, Eighty Eight, LeSabre & LSS ................... "H" Body
Camaro & Firebird ......................................... "F" Body
Catera .................................................... "V" Body
Cavalier & Sunfire ........................................ "J" Body
Century, Grand Prix, Intrigue, Lumina, Monte Carlo &
Regal .................................................... "W" Body
Page 14 of 1691
"E" Body ................................. Harrison HD6/HT6 6-Cyl.
"F" Body
3.8L Engine ................................. Harrison V5 5-Cyl.
5.7L Engine ................................. Harrison V7 7-Cyl.
"G" Body
Aurora ................................. Harrison HD6/HT6 6-Cyl.
Riviera ..................................... Harrison V5 5-Cyl.
"H" Body ...................................... Harrison V5 5-Cyl.
"J" Body ...................................... Harrison V5 5-Cyl.
"K" Body ................................. Harrison HD6/HT6 6-Cyl.
"M" Body ..................................... Nippondenso 10-Cyl.
"N" Body ...................................... Harrison V5 5-Cyl.
"S" Body ...................................... Harrison V5 5-Cyl.
"V" Body ...................................... Harrison V5 5-Cyl.
"W" Body ...................................... Harrison V5 5-Cyl.
"Y" Body ...................................... Harrison V7 7-Cyl.
"Z" Body ....................................... Zexel Rotary Vane
(1) - Body codes are determined by fourth character of VIN code.
\
\
\
\
\
\
\
COMPRESSOR APPLICATIONS (LIGHT TRUCKS & VANS) \
\
\
\
\
\
\
Application Compressor
Chrysler Corp.
Dakota & Ram Pickup ........................ Sanden SD-7H15 7-Cyl.
Durango .................................... Sanden SD-7H15 7-Cyl.
Caravan, Town & Country, & Voyager .... Nippondenso 10PA17 10-Cyl.
Ram Van/Wagon ............................... Sanden TR-105 Scroll
Ford Motor Co.
"E" Series Van ................................ Ford FS-10 10-Cyl.
Expedition & Navigator ........................ Ford FS-10 10-Cyl.
Explorer & Mountaineer ........................ Ford FS-10 10-Cyl.
"F" Series Pickup
Except Super Duty ........................... Ford FS-10 10-Cyl.
Super Duty ............................... Sanden SD-7H15 7 Cyl.
Ranger ........................................ Ford FS-10 10-Cyl.
Villager ........................................... FS-10 10-Cyl.
Windstar ...................................... Ford FS-10 10-Cyl.
General Motors ( 1)
"C" & "K" Series ......................... Harrison HD6/HT6 6-Cyl.
"G" Series .................................... Harrison V5 5-Cyl.
"J" Series ................................... Nippondenso 10-Cyl.
"L" & "M" Series ......................... Harrison HD6/HT6 6-Cyl.
"P" Series ............................... Harrison HD6/HT6 6-Cyl.
"S" & "T" Series
2.2L ........................................ Harrison V7 7-Cyl.
4.3L ................................... Harrison HD6/HT6 6-Cyl.
"U" Series .................................... Harrison V5 5-Cyl.
Jeep
Cherokee ................................... Sanden SD-7H15 7-Cyl.
Grand Cherokee ........................ Nippondenso 10PA17 10-Cyl.
Wrangler ................................... Sanden SD-7H15 7-Cyl.
( 1) - Series codes are determined by fifth character of VIN code.
\
\
\
\
\
\
\
CAPACITIES
NOTE: Always refer to underhood A/C specification label in engine
compartment or A/C compressor label while servicing A/C
Page 15 of 1691
system. If A/C specification label and specifications in this
article differ, use underhood label specifications.
REFRIGERANT OIL & R-134a REFRIGERANT CAPACITY (CARS)
\
\
\
\
\
\
\
Application ( 1) Oil Oz. Refrigerant Oz.
Chrysler Corp.
Avenger & Sebring Coupe
2.0L (DOHC) ...................... 2.7-4.1 ......... 24.7-26.1\
2.5L (SOHC) ...................... 5.7-6.4 ......... 24.7-26.1\
Breeze, Cirrus & Stratus ............. 5.0 ................ 20.0
Concorde, Intrepid, LHS & 300M ....... 5.0 ................ 28.0
Neon ................................. 6.8 ................ 28.0
Sebring Convertible .................. 5.0 ................ 20.0
Ford Motor Co.
Continental .......................... 7.0 ................ 34.0
Contour, Cougar & Mystique ........... ( 1) ................. ( 1)
Crown Victoria & Grand Marquis ....... 7.0 ................ 38.0
Escort, Coupe & Tracer ............... 7.0 ................ 28.0
Mustang .............................. 7.0 ................ 34.0
Sable & Taurus ....................... 7.0 ................ 34.0
Town Car ............................. 7.0 ................ 38.0
General Motors
"C" Body ............................. 9.0 ................ 32.0
"E" & "K" Bodies ................ ( 1) 8.0-9.0 ............. 32.0
"F" Body ............................. 9.0 ................ 24.0
"G" Body
With HD6/HT6 Compressor ............ 8.0 ................ 32.0
With V5 Compressor ................. 9.0 ................ 32.0
"H" Body ............................. 9.0 ................ 32.0
"J" Body ............................. 9.0 ................ 24.0
"M" Body ............................. 3.4 ........... 19.0-21.0
"N" Body ............................. 9.0 ................. ( 2)
"S" Body ......................... ( 3) 4.1 ........... 22.9-26.5
"V" Body ............................. 9.0 ................ 33.5
"W" Body ............................. 9.0 ................ 30.0
"Y" Body ............................. 9.0 ................ 24.0
"Z" Body ............................. 5.0 ................ 24.0
( 1) - Total system capacity, unless otherwise noted. Refer to
underhood A/C specification label in engine compartment for
specified oil type.
( 2) - Refrigerant capacity for Alero and Grand Am is 36.0 ounces.
Refrigerant capacity for Cutlass and Malibu is 28.0 ounces.
( 3) - Compressor oil capacity.
\
\
\
\
\
\
\
REFRIGERANT OIL & R-134a REFRIGERANT CAPACITY (LIGHT TRUCKS & VANS) \
\
\
\
\
\
\
Application ( 1) Oil Oz. Refrigerant Oz.
Chrysler Corp.
Caravan, Town & Country, & Voyager
Without Rear Unit ................... 9.0 ............... 34.0
With Rear Unit ..................... 13.4 ............... 44.0
Dakota ................................ 8.1 ............... 28.0
Durango
Without Rear Unit ................... 5.5 ............... 28.0
With Rear Unit ...................... 8.0 ............... 30.0
Ram Pickup ............................ 8.1 ............... 30.0
Ram Van/Wagon
Without Rear Unit ................... 8.0 ............... 34.0
Page 20 of 1691
Evaporator
Except "U" Series .......................................... 3.0
"U" Series ................................................. (4)
( 1) - Add amount drained from old accumulator/receiver-drier plus one
ounce.
( 2) - Ensure replacement compressor contains the same amount of
refrigerant oil as was drained from old compressor.
( 3) - Drain and measure refrigerant oil from old compressor. If old
compressor had less than one ounce, add 2 ounces of refrigerant
oil to replacement compressor. If old compressor had more than
one ounce, add the same amount of refrigerant oil to replacement
compressor.
( 4) - Information not available from manufacturer.
\
\
\
\
\
\
\
NIPPONDENSO 10-CYLINDER
General Motors (Metro & Tracker)
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove A/C compressor. Drain, measure
and discard refrigerant oil from old compressor. Drain refrigerant oil
from replacement compressor. Add refrigerant oil to replacement
compressor equal to amount drained from oil compressor.
2) Add specified amount of refrigerant oil to components that
are replaced during compressor replacement. See NIPPONDENSO 10-
CYLINDER COMPONENT REFRIGERANT OIL CAPACITIES table. Install A/C
compressor. Evacuate and charge system. Perform leak test.
NIPPONDENSO 10-CYLINDER COMPONENT REFRIGERANT OIL CAPACITIES
\
\
\
\
\
\
\
Component Ounces
Compressor ..................................................... 3.0
Condenser .................................................. 0.7-1.0
Receiver-Drier ................................................. 0.3
System Total ................................................... 3.4
\
\
\
\
\
\
\
NIPPONDENSO 10PA17/10PA17C 10-CYL.
Chrysler Corp. (Avenger & Sebring Coupe)
1) Remove A/C compressor. Drain and measure oil from old
compressor. Replacement compressor is shipped with 3.4 ounces of oil.
From replacement compressor, drain the difference between system oil
capacity and amount of oil drained from replacement compressor.
2) Add specified amount of refrigerant oil to components that
are replaced during compressor replacement. See 10PA17/10PA17C
COMPONENT REFRIGERANT OIL CAPACITIES table. When replacing components
listed, DO NOT exceed system total capacity.
Chrysler Corp. & Jeep (Caravan, Concorde, Grand Cherokee,
Intrepid, LHS, Neon, Town & Country, Voyager & 300M)
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Disconnect refrigerant hoses at
compressor. Remove compressor bolts and A/C compressor.
2) Remove suction port on top of A/C compressor, and drain
and measure oil. On Grand Cherokee, add the same amount of oil drained
from old compressor to replacement compressor.
3) On all other models, add amount of oil to compressor equal
to the total system capacity minus amount retained in components that
are not being replaced. See 10PA17/10PA17C COMPONENT REFRIGERANT OIL
CAPACITIES table. Install A/C compressor. Evacuate and charge A/C
Page 21 of 1691
system. Perform leak test.
10PA17/10PA17C COMPONENT REFRIGERANT OIL CAPACITIES
\
\
\
\
\
\
\
Component Ounces
Avenger & Sebring Coupe
Compressor ................................................... (1)
Condenser .................................................... 1.4
Evaporator ................................................... 1.4
Receiver-Drier ............................................... 0.3
Suction Hose ................................................. 0.3
System Total ................................................. 2.7
Concorde, Intrepid, LHS & 300M
Compressor ............................................... ( 1) 5.0
Condenser .................................................... 1.0
Evaporator ................................................... 2.0
Receiver-Drier ............................................... 1.0
Leaking/Blown Line ........................................... 1.5
System Total ................................................. 5.0
Caravan, Town & Country, & Voyager
With Rear Unit
Compressor ................................................. ( 1)
Condenser .................................................. 1.0
Front Evaporator ........................................... 2.0
Rear Evaporator ............................................ 2.0
Receiver-Drier ............................................. 1.0
A/C System Total ........................................... 7.4
Without Rear Unit
Compressor ................................................. ( 1)
Condenser .................................................. 1.0
Evaporator ................................................. 2.0
Receiver-Drier ............................................. 1.0
A/C System Total ........................................... 5.0
Grand Cherokee
Accumulator .................................................. 4.0
Compressor ................................................... ( 2)
Condenser .................................................... 1.0
Evaporator ................................................... 2.0
Refrigerant Line ............................................. 1.0
System Total ................................................. 7.4
Neon
Compressor ................................................... ( 3)
Condenser .................................................... 1.0
Evaporator ................................................... 2.0
Receiver-Drier ............................................... 1.0
Refrigerant Line ............................................. 1.5
System Total ................................................. 6.8
( 1) - Replacement compressor is shipped with specified amount of
refrigerant oil.
( 2) - Ensure replacement compressor contains the same amount of
refrigerant oil as was drained from old compressor.
( 3) - Add amount drained from removed compressor, plus amount
recovered from system, to replacement compressor. DO NOT exceed
system total.
\
\
\
\
\
\
\
SANDEN SCROLL
Ford Motor Co. (Taurus 3.4L SHO)
1) Slowly discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove A/C compressor. Drain as much
Page 25 of 1691
A/C C O M PR ESSO R S ER VIC IN G
1999 D odge P ic ku p R 1500
1999 GENERAL SERVICING
A/C Compressor Servicing
All Models
* PLEASE READ THIS FIRST *
NOTE: Always refer to underhood A/C specification label in engine
compartment or A/C compressor label while servicing A/C
system. If A/C specification label and A/C COMPRESSOR
SERVICING article specifications differ, use underhood label
specifications.
BODY DESIGNATIONS
BODY DESIGNATIONS (CHRYSLER CORP. CARS) \
\
\
\
\
\
\
Model ( 1) Body Designation
Avenger & Sebring Coupe ................................ "FJ22" Body
Breeze, Cirrus & Stratus ................................. "JA" Body
Concorde, Intrepid, LHS & 300M ........................... "LH" Body
Neon ..................................................... "PL" Body
Sebring Convertible ...................................... "JX" Body
( 1) - Body codes are determined by fifth character of VIN code.
\
\
\
\
\
\
\
BODY DESIGNATIONS (CHRYSLER CORP. LIGHT TRUCKS & VANS) \
\
\
\
\
\
\
Model Body Designation
Caravan, Town & Country, & Voyager ..................... "NS" Series
Dakota ................................................. "AN" Series
Durango ................................................ "DN" Series
Ram Pickup .......................................... "BR/BE" Series
Ram Van/Wagon .......................................... "AB" Series
\
\
\
\
\
\
\
BODY DESIGNATIONS (FORD MOTOR CO. LIGHT TRUCKS & VANS) \
\
\
\
\
\
\
Model Body Designation
Explorer & Mountaineer .................................. "U" Series
Pickup .................................................. "F" Series
Ranger .................................................. "R" Series
Van ..................................................... "E" Series
\
\
\
\
\
\
\
BODY DESIGNATIONS (GENERAL MOTORS CARS) \
\
\
\
\
\
\
Model ( 1) Body Designation
Alero, Cutlass, Grand Am & Malibu ......................... "N" Body
Aurora & Riviera .......................................... "G" Body
Bonneville, Eighty Eight, LeSabre & LSS ................... "H" Body
Camaro & Firebird ......................................... "F" Body
Catera .................................................... "V" Body
Cavalier & Sunfire ........................................ "J" Body
Page 27 of 1691
General Motors (1)
"C" Body ...................................... Harrison V5 5-Cyl.
"E" Body ................................. Harrison HD6/HT6 6-Cyl.
"F" Body
3.8L Engine ................................. Harrison V5 5-Cyl.
5.7L Engine ................................. Harrison V7 7-Cyl.
"G" Body
Aurora ................................. Harrison HD6/HT6 6-Cyl.
Riviera ..................................... Harrison V5 5-Cyl.
"H" Body ...................................... Harrison V5 5-Cyl.
"J" Body ...................................... Harrison V5 5-Cyl.
"K" Body ................................. Harrison HD6/HT6 6-Cyl.
"M" Body ..................................... Nippondenso 10-Cyl.
"N" Body ...................................... Harrison V5 5-Cyl.
"S" Body ...................................... Harrison V5 5-Cyl.
"V" Body ...................................... Harrison V5 5-Cyl.
"W" Body ...................................... Harrison V5 5-Cyl.
"Y" Body ...................................... Harrison V7 7-Cyl.
"Z" Body ....................................... Zexel Rotary Vane
( 1) - Body codes are determined by fourth character of VIN code.
\
\
\
\
\
\
\
COMPRESSOR APPLICATIONS (LIGHT TRUCKS & VANS) \
\
\
\
\
\
\
Application Compressor
Chrysler Corp.
Dakota & Ram Pickup ........................ Sanden SD-7H15 7-Cyl.
Durango .................................... Sanden SD-7H15 7-Cyl.
Caravan, Town & Country, & Voyager .... Nippondenso 10PA17 10-Cyl.
Ram Van/Wagon ............................... Sanden TR-105 Scroll
Ford Motor Co.
"E" Series Van ................................ Ford FS-10 10-Cyl.
Expedition & Navigator ........................ Ford FS-10 10-Cyl.
Explorer & Mountaineer ........................ Ford FS-10 10-Cyl.
"F" Series Pickup
Except Super Duty ........................... Ford FS-10 10-Cyl.
Super Duty ............................... Sanden SD-7H15 7 Cyl.
Ranger ........................................ Ford FS-10 10-Cyl.
Villager ........................................... FS-10 10-Cyl.
Windstar ...................................... Ford FS-10 10-Cyl.
General Motors ( 1)
"C" & "K" Series ......................... Harrison HD6/HT6 6-Cyl.
"G" Series .................................... Harrison V5 5-Cyl.
"J" Series ................................... Nippondenso 10-Cyl.
"L" & "M" Series ......................... Harrison HD6/HT6 6-Cyl.
"P" Series ............................... Harrison HD6/HT6 6-Cyl.
"S" & "T" Series
2.2L ........................................ Harrison V7 7-Cyl.
4.3L ................................... Harrison HD6/HT6 6-Cyl.
"U" Series .................................... Harrison V5 5-Cyl.
Jeep
Cherokee ................................... Sanden SD-7H15 7-Cyl.
Grand Cherokee ........................ Nippondenso 10PA17 10-Cyl.
Wrangler ................................... Sanden SD-7H15 7-Cyl.
( 1) - Series codes are determined by fifth character of VIN code.
\
\
\
\
\
\
\
FORD FS-10 10-CYLINDER
Page 29 of 1691
Removal
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove compressor. Using a spanner
wrench or clutch holder, remove clutch plate bolt. Discard bolt.
Thread an 8-mm bolt into clutch plate and remove clutch plate and
shims.
2) Remove shaft felt seal. Using low pressure compressed air
and a lint-free cloth, thoroughly clean seal inside and outside of
compressor nose area. Using Snap Ring Remover (T89P-19623-DH), rotate
eye of snap ring. Pull up snap ring while holding snap ring at an
angle.
3) Position Shaft Seal Remover (T89P-19623-BH) over
compressor shaft. Push shaft seal remover downward against seal.
Ensure end of shaft seal remover engages inside of seal.
4) Rotate shaft seal remover handle clockwise to expand
remover tip inside seal. Pull shaft seal from compressor.
Installation
1) Lubricate shaft seal protector and shaft seal with
refrigerant oil. Replacement Seal Kit (19D665) includes Shaft Seal
Protector (T94P-19623-F).
2) Coat shaft seal and protector with clean refrigerant oil.
Install shaft seal on shaft seal protector so lip of seal is toward
large end of shaft seal protector. Install shaft seal protector onto
compressor shaft.
3) Using Shaft Seal Replacer (T89P-19623-AH), slowly push
shaft seal down until it is seated. Remove shaft seal installer and
protector. Install new shaft seal snap ring. Rotate compressor shaft
about 10 revolutions and leak test shaft seal installation.
4) Install new shaft seal felt. Install clutch plate. Install
new clutch plate bolt, and tighten it to 98-123 INCH lbs. (11-14 N.m).\
5) Using a feeler gauge, measure air gap (in 3 places)
between clutch plate and pulley assembly mating surface. Air gap
should be 0.014-0.033" (0.36-0.84 mm). If air gap is not as specified,\
add or remove shims as necessary.
HARRISON HD6/HT6 & HD6/HR-6HE 6-CYL., V5 5-CYL. & V7 7-CYL.
CLUTCH ASSEMBLY
CAUTION: DO NOT hammer on compressor shaft to remove clutch plate, as
compressor damage will result.
Removal
1) Remove compressor from vehicle. Place compressor in
Holding Fixture (HD6/HT6 and HD6/HR-6HE compressor use J-33026; on V5
or V7 compressor use J-34992 or J-41790). On V5 or V7 compressor,
remove dust cover (if equipped). Use Clutch Plate Spanner (J-33027-A)\
to hold clutch plate and remove compressor shaft nut using Shaft Nut
Socket (J-33022). See Fig. 2 or 3.
2) On all compressors, using Clutch Plate Remover/Installer
(J-33013-B), remove compressor clutch plate and hub. See Fig. 2 or 3.
Hold remover body and turn center screw into remover body to remove
clutch plate and hub. Ensure forcing tip on remover/installer center
screw is flat or end of shaft/axial plate will be damaged. Remove
shaft key.
3) Remove snap ring. Install Puller Guide (J-33023-A) on
front head. Position Pulley and Bearing Puller (J-41552 for HD6/HT6
and HD6/HR-6HE or J-33020 for V5 or V7 compressor) into inner circle
of slots on pulley assembly. Turn puller clockwise in slots. Tighten
puller and remove pulley assembly.
Page 33 of 1691
NOTE: It is not necessary to replace shaft seal because of a small
amount of oil found on adjacent surfaces. A small amount of
oil is normal for lubrication purposes. Shaft seal should
only be replaced after a confirmed refrigerant leak is
found.
Removal
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Loosen and reposition compressor in
mounting bracket. Remove clutch plate and hub assembly. See CLUTCH
ASSEMBLY. See Fig. 2 or 3.
2) Remove shaft seal snap ring. Ensure all surfaces around
seal are clean. Insert Shaft Seal Remover/Installer (J-23128-A) into
shaft seal. Rotate handle clockwise to seat seal remover/installer in
seal. Remove shaft seal. Using "O" Ring Remover (J-9553-01), remove
"O" ring. Ensure shaft and inside of compressor neck are clean and
free of foreign material. Thoroughly clean "O" ring groove in front
head.
Installation
1) Install Shaft Seal Protector (J-34614) over compressor
shaft. With shaft seal protector in place, lubricate "O" ring with
refrigerant oil and install it on "O" Ring Installer (J-33011).
2) Insert "O" ring installer in compressor until it bottoms.
Move slide on "O" ring installer downward until "O" ring is released
into groove. Rotate installer to seat "O" ring. Remove "O" ring
installer.
3) Lubricate shaft seal with refrigerant oil. Install shaft
seal onto Seal Installer (J-23128-A). Install shaft seal so flared
side of lip seal is installed toward compressor. Expand seal using
shaft seal remover/installer. Install shaft seal on Seal Protector (J-
34614). Place seal protector over shaft.
4) Push shaft seal into compressor using a rotary motion
until seal bottoms. Install new snap ring with flat side against seal.
Install clutch plate and hub assembly onto compressor shaft. See
CLUTCH ASSEMBLY.
NIPPONDENSO 10-CYLINDER
CLUTCH ASSEMBLY
Removal & Installation (Metro & Tracker)
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove A/C compressor. Drain, measure
and discard refrigerant oil from compressor.
2) Using Clutch Plate Holder/Remover (J-41384) remove clutch\
plate nut, washer and clutch plate from compressor drive shaft. Remove
clutch pulley snap ring and shim. Using a plastic mallet, gently tap
and remove clutch pulley. Remove clutch coil wire retainer from
compressor. Remove clutch coil snap ring and clutch coil. See Fig. 4.
3) Install clutch coil and snap ring. Attach clutch coil wire
retainer to compressor. Install clutch pulley, snap ring and shim.
Install clutch plate to compressor shaft. Measure air gap between
clutch pulley and clutch plate.
4) Air gap should be 0.014-0.026" (0.35-0.65 mm). Add or
remove shims as necessary. Install compressor shaft nut and washer.
Tighten compressor shaft nut to 11-15 ft. lbs. (15-20 N.m). After
repairs, add NEW refrigerant oil to compressor equal to amount
drained. To complete installation, reverse removal procedure.
SHAFT SEAL
Page 42 of 1691
A/C -H EA TE R S YSTE M T R O UBLE S H O OTIN G
1999 D odge P ic ku p R 1500
1999 MANUAL A/C-HEATER SYSTEMS
Trouble Shooting - Cars & Trucks
CHRYSLER
Avenger, Breeze, Caravan, Cirrus, Concorde, Dakota, Durango,
Intrepid, LHS, Neon, Ram Pickup, Ram Van/Wagon, Sebring Convertible,
Sebring Coupe, Stratus, Town & Country, Voyager, 300M
A/C SYSTEM DIAGNOSIS
RAPID COMPRESSOR CLUTCH CYCLING
Some possible causes of rapid compressor clutch cycling,
clutch cycles 10 or more times per minute, include:
* Low refrigerant system charge.
* Faulty low pressure cycling clutch switch.
* Faulty PCM.
COMPRESSOR WILL NOT ENGAGE
Some possible causes of compressor not engaging with high and
low side system pressures equal include:
* No refrigerant in system.
* Faulty fuse.
* Faulty compressor clutch coil.
* Faulty compressor clutch relay.
* Faulty electronic cycling clutch switch.
* Improperly installed or faulty low pressure cycling clutch
switch.
* Faulty low pressure cut-off switch.
* Faulty high pressure cut-off switch.
* Faulty PCM.
* Faulty A/C-heater control panel.
TEMPERATURE IS TOO HIGH WITH A/C ON
Some possible causes of high temperature output at center
panel when A/C system pressure is normal include:
* Excessive oil charge in refrigerant.
* Temperature control cable improperly installed or faulty.
* Blend-air door inoperative, obstructed or sealing
improperly.
* Blend door actuator not calibrated.
LOW SIDE PRESSURE IS LOW-TO-NORMAL & HIGH SIDE PRESSURE IS
LOW
Some possible causes of low side system pressure being lower-
to-normal and high side system pressure being too low include:
* Low refrigerant system charge.
* Refrigerant flow through accumulator is restricted.
* Refrigerant flow through evaporator is restricted.
* Faulty compressor.
LOW SIDE PRESSURE IS HIGH-TO-NORMAL & HIGH SIDE PRESSURE IS