air filter DODGE RAM 1500 1998 2.G Manual Online

AUTOMATIC TRANSMISSION - 45RFE/545RFE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 45RFE/545RFE
DESCRIPTION........................312
OPERATION..........................313
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION.....................314
DIAGNOSIS AND TESTING -
PRELIMINARY.......................314
DIAGNOSIS AND TESTING - ROAD
TESTING...........................314
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST....................316
DIAGNOSIS AND TESTING - AIR CHECKING
TRANSMISSION CLUTCH OPERATION....317
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK................318
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR.....................318
REMOVAL............................318
DISASSEMBLY........................320
CLEANING...........................326
INSPECTION.........................326
ASSEMBLY...........................326
INSTALLATION........................333
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS.............337
SPECIFICATIONS
TRANSMISSION.....................358
SPECIAL TOOLS
RFE TRANSMISSION.................359
4C RETAINER/BULKHEAD
DISASSEMBLY........................362
ASSEMBLY...........................363
ADAPTER HOUSING SEAL
REMOVAL............................364
INSTALLATION........................364
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM
DESCRIPTION........................364
OPERATION..........................364
DIAGNOSIS AND TESTING - BRAKE
TRANSMISSION SHIFT INTERLOCK......364
ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK...................365
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL.............366
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID.......................366DIAGNOSIS AND TESTING - FLUID
CONTAMINATION....................366
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK............................366
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT...............367
STANDARD PROCEDURE - TRANSMISSION
FILL...............................368
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE.............................368
REMOVAL............................369
INSTALLATION........................370
ADJUSTMENTS
GEARSHIFT CABLE..................370
HOLDING CLUTCHES
DESCRIPTION........................371
OPERATION..........................372
INPUT CLUTCH ASSEMBLY
DESCRIPTION........................373
OPERATION..........................373
DISASSEMBLY........................374
ASSEMBLY...........................378
INPUT SPEED SENSOR
DESCRIPTION........................382
OPERATION..........................382
REMOVAL............................382
INSTALLATION........................382
LINE PRESSURE (LP) SENSOR
DESCRIPTION........................382
OPERATION..........................383
REMOVAL............................383
INSTALLATION........................383
LOW/REVERSE CLUTCH
DISASSEMBLY........................384
CLEANING...........................385
INSPECTION.........................385
ASSEMBLY...........................385
OIL PUMP
DESCRIPTION........................386
OPERATION..........................386
STANDARD PROCEDURE - OIL PUMP
VOLUME CHECK.....................387
DISASSEMBLY........................388
CLEANING...........................390
INSPECTION.........................390
ASSEMBLY...........................390
OIL PUMP FRONT SEAL
REMOVAL............................391
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 311

TRANSMISSION IDENTIFICATION
Transmission identification numbers are stamped
on the left side of the case just above the oil pan
sealing surface (Fig. 1). Refer to this information
when ordering replacement parts. A label is attached
to the transmission case above the stamped numbers.
The label gives additional information which may
also be necessary for identification purposes.
GEAR RATIOS
The 45RFE gear ratios are:
1st .................................3.00:1
2nd.................................1.67:1
2nd Prime...........................1.50:1
3rd.................................1.00:1
4th .................................0.75:1
Reverse.............................3.00:1
GEAR RATIOS
The 545RFE gear ratios are:
1st .................................3.00:1
2nd.................................1.67:1
2nd Prime...........................1.50:1
3rd.................................1.00:1
4th .................................0.75:1
5th .................................0.67:1
Reverse.............................3.00:1
OPERATION
The 45RFE/545RFE offers full electronic control of
all automatic up and downshifts, and features real-
time adaptive closed-loop shift and pressure control.
Electronic shift and torque converter clutch controls
help protect the transmission from damage due to
high temperatures, which can occur under severe
operating conditions. By altering shift schedules, line
pressure, and converter clutch control, these controls
reduce heat generation and increase transmission
cooling.
To help reduce efficiency-robbing parasitic losses,
the transmissions includes a dual-stage transmission
fluid pump with electronic output pressure control.
Under most driving conditions, pump output pres-
sure greatly exceeds that which is needed to keep the
clutches applied. The 45RFE/545RFE pump-pressure
control system monitors input torque and adjusts the
pump pressure accordingly. The primary stage of the
pump works continuously; the second stage is
bypassed when demand is low. The control system
also monitors input and output speed and, if incipi-
ent clutch slip is observed, the pressure control sole-
noid duty cycle is varied, increasing pressure in
proportion to demand.
A high-travel torque converter damper assembly
allows earlier torque converter clutch engagement to
reduce slippage. Needle-type thrust bearings reduce
internal friction. The 45RFE/545RFE is packaged in
a one-piece die-cast aluminum case. To reduce NVH,
the case has high lateral, vertical and torsional stiff-
ness. It is also designed to maximize the benefit of
the structural dust cover that connects the bottom of
the bell housing to the engine bedplate, enhancing
overall power train stiffness. Dual filters protect the
pump and other components. A pump return filter is
added to the customary main sump filter. Indepen-
dent lubrication and cooler circuits assure ample
pressure for normal transmission operation even if
the cooler is obstructed or the fluid cannot flow due
to extremely low temperatures.
The hydraulic control system design (without elec-
tronic assist) provides the transmission with PARK,
REVERSE, NEUTRAL, SECOND, and THIRD gears,
based solely on driver shift lever selection. This
design allows the vehicle to be driven (in ªlimp-inº
mode) in the event of a electronic control system fail-
ure, or a situation that the Transmission Control
Module (TCM) recognizes as potentially damaging to
the transmission.
The TCM also performs certain self-diagnostic
functions and provides comprehensive information
(sensor data, DTC's, etc.) which is helpful in proper
diagnosis and repair. This information can be viewed
with the DRBtscan tool.
Fig. 1 Transmission Part And Serial Number
Location
1 - IDENTIFICATION NUMBERS (STAMPED)
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 313
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

(43) Remove the park pawl rod and e-clip (Fig. 31).
(44) Remove the park pawl rod guide snap-ring
(Fig. 31).
(45) Remove the park pawl rod guide (Fig. 31).
(46) Remove the park pawl pivot shaft, park pawl,
and spring (Fig. 31).
(47) Remove the manual selector shaft (Fig. 31).
(48) Remove the manual selector shaft seal.
(49) Remove the dipstick tube seal.
CLEANING
The use of crocus cloth is permissible where neces-
sary, providing it is used carefully. When used on shafts,
or valves, use extreme care to avoid rounding off sharp
edges. Sharp edges are vital as they prevent foreign
matter from getting between the valve and valve bore.
Do not reuse oil seals, gaskets, seal rings, or O-rings
during overhaul. Replace these parts as a matter of
course. Also do not reuse snap rings or E-clips that are
bent or distorted. Replace these parts as well.
Lubricate transmission parts with MopartATF +4,
Automatic Transmission Fluid, during overhaul and
assembly. Use petroleum jelly, MopartDoor Ease, or
Ru-Glyde to prelubricate seals, O-rings, and thrust
washers. Petroleum jelly can also be used to hold
parts in place during reassembly.Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent.
Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
that all fluid passages are clear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.
INSPECTION
Inspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repaired with Helicoil thread inserts. However, the
case will have to be replaced if it exhibits any type of
damage or wear.
ASSEMBLY
(1) Clean and inspect all components. Replace any
components which show evidence of excessive wear
or scoring.
(2) Install the cooler filter bypass valve.
(3) Torque the bypass valve to specification. The
valve uses a tapered pipe thread and excessive
torque can damage the transmission case. Tighten
the cooler filter bypass valve to 4.5 N´m (40 in.lbs.).
(4) Install a new selector shaft seal using Seal
Installer 8253 (Fig. 32).
Fig. 31 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
Fig. 32 Install Selector Shaft
1 - SEAL
2 - TOOL 8253
21 - 326 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)

FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL
A low fluid level allows the pump to take in air
along with the fluid. Air in the fluid will cause fluid
pressures to be low and develop slower than normal.
If the transmission is overfilled, the gears churn the
fluid into foam. This aerates the fluid and causing
the same conditions occurring with a low level. In
either case, air bubbles cause fluid overheating, oxi-
dation and varnish buildup which interferes with
valve and clutch operation. Foaming also causes fluid
expansion which can result in fluid overflow from the
transmission vent or fill tube. Fluid overflow can eas-
ily be mistaken for a leak if inspection is not careful.
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID
Burnt, discolored fluid is a result of overheating
which has three primary causes.
(1) Internal clutch slippage, usually caused by low
line pressure, inadequate clutch apply pressure, or
clutch seal failure.
(2) A result of restricted fluid flow through the
main and/or auxiliary cooler. This condition is usu-
ally the result of a faulty or improperly installed
drainback valve, a damaged main cooler, or severe
restrictions in the coolers and lines caused by debris
or kinked lines.
(3) Heavy duty operation with a vehicle not prop-
erly equipped for this type of operation. Trailer tow-
ing or similar high load operation will overheat the
transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary
transmission fluid cooler, a heavy duty cooling sys-
tem, and the engine/axle ratio combination needed to
handle heavy loads.
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION
Transmission fluid contamination is generally a
result of:
²adding incorrect fluid
²failure to clean dipstick and fill tube when
checking level
²engine coolant entering the fluid
²internal failure that generates debris
²overheat that generates sludge (fluid break-
down)
²failure to replace contaminated converter after
repairThe use of non-recommended fluids can result in
transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and eventual failure
due to fluid breakdown and sludge formation. Avoid
this condition by using recommended fluids only.
The dipstick cap and fill tube should be wiped
clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall
into the tube if not removed beforehand. Take the
time to wipe the cap and tube clean before withdraw-
ing the dipstick.
Engine coolant in the transmission fluid is gener-
ally caused by a cooler malfunction. The only remedy
is to replace the radiator as the cooler in the radiator
is not a serviceable part. If coolant has circulated
through the transmission, an overhaul is necessary.
The torque converter should also be replaced when-
ever a failure generates sludge and debris. This is
necessary because normal converter flushing proce-
dures will not remove all contaminants.
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transmssion has too much fluid, the
geartrain churns up foam and cause the same condi-
tions which occur with a low fluid level.
In either case, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transmission vent where it may be mis-
taken for a leak.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
The transmission has a dipstick to check oil level.
It is located on the right side of the engine. Be sure
to wipe all dirt from dipstick handle before removing.
The torque converter fills in both the P (PARK)
and N (NEUTRAL) positions. Place the selector lever
in P (PARK) to be sure that the fluid level check is
accurate.The engine should be running at idle
speed for at least one minute, with the vehicle
on level ground.At normal operating temperature
(approximately 82 C. or 180 F.), the fluid level is cor-
rect if it is in the HOT region (cross-hatched area) on
the oil level indicator. The fluid level will be approx-
21 - 366 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR

(11) Remove the transfer plate from the valve
body. Note the location of all check balls (Fig. 137).
(12) Remove the check balls from the valve body.
(13) Remove the retainers securing the solenoid
switch valve, manual valve, and the low/reverse
switch valve into the valve body and remove the
associated valve and spring. Tag each valve and
spring combination with location information to aid
in assembly. (Fig. 138)
CLEANING
Clean the valve housings, valves, plugs, springs,
and separator plates with a standard parts cleaning
solution only. Do not use gasoline, kerosene, or any
type of caustic solution. (Fig. 139)
Do not immerse any of the electrical components in
cleaning solution. Clean the electrical components by
wiping them off with dry shop towels only.
Dry all except the electrical parts with compressed
air. Make sure all passages are clean and free from
obstructions.Do not use rags or shop towels to
dry or wipe off valve body components. Lint
from these materials can stick to valve body
parts, interfere with valve operation, and clog
filters and fluid passages.
Fig. 137 Check Ball Locations
Fig. 138 Valve Body Components
1 - SOLENOID SWITCH VALVE
2 - MANUAL VALVE
3 - LOW REVERSE SWITCH VALVE
4 - LOW REVERSE ACCUMULATOR
5 - 2ND CLUTCH ACCUMULATOR
6 - UNDERDRIVE ACCUMULATOR
7 - OVERDRIVE ACCUMULATOR
8 - 4TH CLUTCH ACCUMULATOR
9 - CHECK BALLS (7)
21 - 412 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
VALVE BODY (Continued)

BODY
TABLE OF CONTENTS
page page
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS . 1
DIAGNOSIS AND TESTING - WIND NOISE . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY
LUBRICATION.........................3
STANDARD PROCEDURE - HEAT STAKING . . 3
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR........................3
STANDARD PROCEDURE - BUZZ, SQUEAK
& RATTLE...........................11
SPECIFICATIONS - TORQUE..............12SPECIAL TOOLS
BODY..............................14
TAILGATE..............................15
DOOR - FRONT.........................18
DOORS - REAR.........................28
EXTERIOR.............................36
HOOD.................................46
INSTRUMENT PANEL.....................49
INTERIOR..............................62
PAINT.................................73
SEATS................................75
STATIONARY GLASS.....................86
WEATHERSTRIP/SEALS...................91
BODY STRUCTURE......................95
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE AN OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
²AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL ± BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
²DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
²Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
²Always have a fire extinguisher ready for use
when welding.
²Disconnect the negative (-) cable clamp from
the battery when servicing electrical components
that are live when the ignition is OFF. Damage to
electrical system can result.²Do not use abrasive chemicals or compounds
on painted surfaces. Damage to finish can result.
²Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
²Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
DRBODY 23 - 1

REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).
(2) Disassemble the HVAC housing to access the
A/C evaporator (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/HVAC HOUSING -
DISASSEMBLY).
(3) Remove the evaporator temperature sensor
probe from the A/C evaporator.
(4) Lift the A/C evaporator out of the HVAC hous-
ing (Fig. 19).
INSTALLATION
NOTE: If the A/C evaporator is being replaced, add
60 milliliters (2 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
(1) Install the A/C evaporator into the HVAC hous-
ing. Make sure that the evaporator drain is clean
and unrestricted and that the evaporator deflector
shield is installed.
(2) Install the evaporator temperature sensor
probe into the A/C evaporator.
(3) Assemble the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY).
(4) Install the HVAC housing (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).
A/C ORIFICE TUBE
DESCRIPTION
The fixed A/C orifice tube (Fig. 20) is installed in
the liquid line between the outlet of the condenser
and the inlet of the evaporator. The A/C orifice tube
is only serviced as an part of the liquid line.
OPERATION
The fixed A/C orifice tube is used to meter the flow
of liquid refrigerant into the evaporator coil. The
high-pressure liquid refrigerant from the condenser
expands into a low-pressure liquid as it passes
through the metering orifice and diffuser screen of
the A/C orifice tube.
The A/C orifice tube is not serviceable. The A/C ori-
fice tube cannot be repaired and, if faulty or plugged,
it must be replaced as part of the liquid line.
Fig. 19 A/C Evaporator - Typical
1 - PASSENGER SIDE BLEND DOOR LEVER
2 - PASSENGER SIDE BLEND DOOR
3 - EVAPORATOR TEMPERATURE SENSOR WIRE
4 - HVAC HOUSING
5 - A/C EVAPORATOR
6 - EVAPORATOR TEMPERATURE SENSOR PROBE
7 - DRIVER SIDE BLEND DOOR
8 - DRIVER SIDE BLEND DOOR LEVER
Fig. 20 Fixed A/C Orifice Tube - Typical
1 - DIFFUSER SCREEN
2 - O-RING SEALS
3 - INLET FILTER SCREEN
4 - ORIFICE
24 - 60 PLUMBINGDR
A/C EVAPORATOR (Continued)

DIAGNOSIS AND TESTING - A/C ORIFICE TUBE
WARNING: THE LIQUID LINE BETWEEN THE CON-
DENSER OUTLET AND THE A/C ORIFICE TUBE
CAN BECOME HOT ENOUGH TO BURN THE SKIN.
USE EXTREME CAUTION WHEN PERFORMING THE
FOLLOWING TEST.
NOTE: The A/C orifice tube can be checked for
proper operation using the following procedure.
However, the A/C orifice tube is only serviced as a
part of the liquid line. If the results of this test indi-
cate that the A/C orifice tube is obstructed or miss-
ing, the liquid line must be replaced.
(1) Confirm that the refrigerant system is properly
charged. (Refer to 24 - HEATING & AIR CONDI-
TIONING - DIAGNOSIS AND TESTING - A/C PER-
FORMANCE)
(2) Start the engine. Turn on the air conditioning
system and confirm that the compressor clutch is
engaged.
(3) Allow the air conditioning system to operate for
five minutes.
(4) Lightly and cautiously touch the liquid line
near the condenser outlet at the front of the engine
compartment. The liquid line should be hot to the
touch.
(5) Touch the liquid line near the evaporator inlet
at the rear of the engine compartment. The liquid
line should be cold to the touch.
(6) If there is a distinct temperature differential
between the two ends of the liquid line, the A/C ori-
fice tube is in good condition. If there is little or no
detectable temperature differential between the two
ends of the liquid line, the A/C orifice tube is
obstructed or missing and the liquid line must be
replaced.
ACCUMULATOR
DESCRIPTION
The accumulator (Fig. 21) is mounted in the engine
compartment between the evaporator outlet and the
compressor suction port. An integral mounting
bracket is used to secure the accumulator to the dash
panel.
The accumulator cannot be repaired and, if faulty
or damaged, it must be replaced. The rubber O-rings
are available for service replacement.
OPERATION
Refrigerant enters the accumulator canister as a
low pressure vapor through the inlet tube. Any liq-
uid, oil-laden refrigerant falls to the bottom of thecanister, which acts as a separator. A desiccant bag is
mounted inside the accumulator canister to absorb
any moisture which may have entered and become
trapped within the refrigerant system.
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
Fig. 21 Accumulator - Typical
1 - A/C LOW PRESSURE SWITCH (IF EQUIPPED)
2 - PRESSURE SWITCH FITTING
3 - OUTLET TO COMPRESSOR
4 - ANTI-SIPHON HOLE
5 - DESICCANT BAG
6 - OIL RETURN ORIFICE FILTER
7 - VAPOR RETURN TUBE
8 - ACCUMULATOR DOME
9 - O-RING SEAL
10 - INLET FROM EVAPORATOR
DRPLUMBING 24 - 61
A/C ORIFICE TUBE (Continued)

ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY).
(3) Remove the air filter housing cover to gain
access to the accumulator (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM).
(4) Remove the secondary retaining clip from the
spring-lock coupler that secures the suction line to
the accumulator outlet tube (Fig. 22).
(5) Using the proper A/C line disconnect tool, dis-
connect the suction line from the accumulator outlet
tube (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT LINE COUPLER -
REMOVAL).
(6) Remove the O-ring seal from the accumulator
outlet tube fitting and discard.
(7) Install plugs in, or tape over the opened suc-
tion line and the accumulator outlet tube fitting.
(8) Loosen the bolts that secure the accumulator to
the bracket located on the dash panel.
(9) Remove the secondary retaining clip from the
spring-lock coupler that secures the accumulator to
the evaporator outlet tube.
(10) Using the proper A/C line disconnect tool, dis-
connect the accumulator inlet tube fitting from the
evaporator outlet tube (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/REFRIGERANT
LINE COUPLER - REMOVAL).
(11) Remove the O-ring seal from the accumulator
inlet tube fitting and discard.
(12) Install plugs in, or tape over the opened accu-
mulator inlet tube fitting and the evaporator outlet
tube.
(13) Remove the accumulator from the engine com-
partment.
INSTALLATION
NOTE: If the accumulator is being replaced, add 60
milliliters (2 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
(1) Position the accumulator onto the dash panel
bracket in the engine compartment. Do not tighten
the bolts at this time.
(2) Remove the tape or plugs from the accumulator
inlet tube fitting and the evaporator outlet tube.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the accumulator inlet
tube fitting. Use only the specified O-ring as it is
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the A/C compressor in the vehicle.
(4) Connect the accumulator inlet tube fitting to
the evaporator outlet tube (Refer to 24 - HEATING &AIR CONDITIONING/PLUMBING/REFRIGERANT
LINE COUPLER - INSTALLATION).
(5) Install the secondary retaining clip onto the
spring-lock coupler that secures the accumulator
inlet tube fitting to the evaporator outlet tube.
(6) Tighten the accumulator bracket bolts to 4.5
N´m (40 in. lbs.).
(7) Remove the tape or plugs from the suction line
fitting and the accumulator outlet tube.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the accumulator out-
let tube fitting. Use only the specified O-ring as it is
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the A/C compressor in the vehicle.
(9) Connect the suction line to the accumulator
outlet tube (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/REFRIGERANT LINE COU-
PLER - INSTALLATION).
(10) Install the secondary retaining clip onto the
spring-lock coupler that secures the suction line to
the accumulator outlet tube.
(11) Install the air filter housing cover to gain
access to the accumulator (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM).
Fig. 22 A/C Accumulator - Typical
1 - RH INNER FENDER
2 - ACCUMULATOR INLET TUBE
3 - A/C LINE SECONDARY RETAINING CLIP
4 - EVAPORATOR OUTLET TUBE
5 - BOLTS (2)
6 - ACCUMULATOR
7 - SUCTION LINE
8 - A/C LOW PRESSURE SERVICE PORT
9 - A/C LINE SECONDARY RETAINING CLIP
24 - 62 PLUMBINGDR
ACCUMULATOR (Continued)

EXCESSIVE OIL CONSUMPTION
Although the PCM monitors engine exhaust oxygen
content when the system is in closed loop, it cannot
determine excessive oil consumption.
THROTTLE BODY AIR FLOW
The PCM cannot detect a clogged or restricted air
cleaner inlet or filter element.
VACUUM ASSIST
The PCM cannot detect leaks or restrictions in the
vacuum circuits of vacuum assisted engine control
system devices. However, these could cause the PCM
to store a MAP sensor diagnostic trouble code and
cause a high idle condition.PCM SYSTEM GROUND
The PCM cannot determine a poor system ground.
However, one or more diagnostic trouble codes may
be generated as a result of this condition. The mod-
ule should be mounted to the body at all times, also
during diagnostic.
PCM CONNECTOR ENGAGEMENT
The PCM may not be able to determine spread or
damaged connector pins. However, it might store
diagnostic trouble codes as a result of spread connec-
tor pins.
DREMISSIONS CONTROL 25 - 9
EMISSIONS CONTROL (Continued)