DODGE RAM 1999 Service Repair Manual

Fig. 12: Poor R-134a Refrigerant Circulation
Fig. 13: No R-134a Refrigerant Circulation

Fig. 14: Insufficient Cooling Of Condenser Or R-134a Refrigerant
Overcharge

Fig. 15: Air In R-134a System

Fig. 16: Expansion Valve Improperly Mounted Or Heat Sensing Tube
Defective (Opening Too Wide)
Fig. 17: Compressor Malfunction

ORIFICE TUBE REPLACEMENT
CHRYSLER CORP.
Removal & Installation (Dakota)
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
liquid line at condenser outlet tube. Cover open refrigerant fittings
to protect from moisture and dirt.
2) Using 2 wrenches, loosen tube fitting and separate front
half of liquid line from rear half of liquid line. Using needle nose
pliers, remove fixed orifice tube from rear half of liquid line. Note
fixed orifice tube orientation for correct installation.
3) To install, reverse removal procedure. Ensure fixed
orifice tube is positioned correctly. Evacuate, charge, and leak test
A/C system. Ensure A/C system operates properly.
NOTE: On Ram Pickup, if the fixed orifice tube is faulty or
plugged, the liquid line and orifice tube must be replaced as
an assembly.
Removal & Installation (Ram Pickup)
Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
liquid line from evaporator inlet and condenser outlet tubes. Cover
open refrigerant fittings to protect from moisture and dirt.
Disconnect liquid line retaining clips. Remove liquid line and orifice
tube. To install, reverse removal procedure. Evacuate, charge, and
leak test A/C system. Ensure A/C system operates properly.
FORD MOTOR CO.
NOTE: Replace orifice tube whenever compressor is replaced. Fixed
orifice tube is located in the condenser-to-evaporator liquid
line.
NOTE: DO NOT use pliers to remove fixed orifice tube or twist
orifice tube in liquid line. Doing so will cause plastic
orifice tube body to break inside condenser-to-evaporator
liquid line.
Fixed Orifice Tube Replacement (Except Continental, Mustang &
Villager)
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. On Contour
and Mystique, move power steering fluid reservoir to one side without
disconnecting hoses.
2) On all models, disconnect condenser-to-evaporator
discharge (liquid) line. Remove and discard "O" rings from line. Pour
a small amount of refrigerant oil into inlet to lubricate orifice "O"
rings.
3) Insert orifice tube remover/installer into tube and turn
tool to right to engage tangs on orifice tube. See Fig. 18. Hold "T"
handle of tool and slowly tighten nut down onto discharge line to
slowly pull orifice tube out. If orifice tube breaks off when removal
is attempted, use orifice tube extractor to pull the broken section
out. See Fig. 19.
4) Ensure replacement orifice tube is fitted with "O" ring(s)\
lubricated with clean refrigerant oil. Insert tube with short end
toward evaporator, until seated. Reconnect high pressure line. On
Contour and Mystique, tighten connection to 18 ft. lbs. (24 N.m).

Fig. 18: Removing Orifice Tube (Typical)
Courtesy of ford motor co.

Fig. 19: Removing Broken Orifice Tube (Typical)
Courtesy of ford motor co.
NOTE: On Continental, Mustang and Villager, if orifice tube is
faulty or plugged, liquid line and orifice tube must be
replaced as an assembly or an orifice tube replacement kit
must be installed.
Orifice Tube Replacement Kit (Continental & Mustang)
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove condenser-to-evaporator liquid
line from vehicle. Locate orifice tube in metal portion of liquid
line, near bend (indented notches or circular depression). See Fig. 20
.
2) Cut a 2.5" (63.5 mm) section from liquid line, at least 1\
"
(25.4 mm) from start of bend in line and discard. Clean out liquid
line to remove contaminants.
3) Lubricate orifice tube replacement kit compression nuts
and rings with refrigerant oil and install on liquid line. See Fig. 21
. Ensure flow direction arrow points toward evaporator. Ensure liquid
line is properly aligned for installation. Tighten compression nuts to
65-69 ft. lbs. (88-94 N.m).
4) To complete installation, reverse removal procedure.
Lubricate "O" rings with refrigerant oil. Evacuate, charge and leak

test system. Ensure A/C system is operating properly.
Orifice Tube Replacement Kit (Villager)
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Drain engine coolant to a level below
thermostat. Remove upper radiator hose and bracket to gain access to
condenser end of liquid line. Remove condenser-to-evaporator liquid
line from vehicle.
2) Locate orifice tube in metal portion of liquid line, at
indentation. See Fig. 20. Make a 4" (102 mm) index line on liquid line
with indentation at the midpoint. Cut a 2.5" (63.5 mm) section from
liquid line with indentation in the middle, at least 1" (25.4 mm) from\
start of closest bend. Clean out liquid line to remove contaminants.
3) Lubricate orifice tube replacement kit compression nuts
and rings with refrigerant oil and install on liquid line. See Fig. 21
. Ensure flow direction arrow points toward evaporator. Ensure index
line on liquid line is properly aligned for installation. Tighten
compression nuts to 65-70 ft. lbs. (88-95 N.m).
4) To complete installation, reverse removal procedure.
Lubricate "O" rings with refrigerant oil. Evacuate, charge and leak
test system. Ensure A/C system is operating properly.
Fig. 20: Locating Orifice Tube (Continental & Mustang Shown; Villager
Is Similar)
Courtesy of ford motor co.

Fig. 21: Installing Orifice Tube Kit (Continental & Mustang Shown;
Villager Is Similar)
Courtesy of ford motor co.
GENERAL MOTORS
Removal ("C", "E", "K" & "H" Body)
1) Locate orifice tube. See ORIFICE TUBE LOCATION &
REMOVER/INSTALLER APPLICATION table. Discharge A/C system, using
approved recovery/recycling equipment. Disconnect liquid line
retaining clips.
2) Disconnect liquid line, at orifice tube location, between
evaporator and condenser. Use Dual "O" Ring Joint Separator (J-38042)
to hold pressure against liquid line female nut while loosening nut,
if necessary. Remove and discard liquid line "O" rings using a
nonmetallic tool so seal surface is not damaged.
3) Remove orifice tube using specified orifice tube remover.
See ORIFICE TUBE LOCATION & REMOVER/INSTALLER APPLICATION table.
Installation
1) Install liquid line "O" rings. Lubricate inside of

evaporator inlet line and "O" rings with refrigerant oil. Lubricate
orifice tube and "O" ring with refrigerant oil. Insert orifice tube
into evaporator inlet line with short screen toward condenser.
2) Tighten liquid line nut to 18 ft. lbs. (24 N.m). To
complete installation, reverse removal procedure. Evacuate, charge,
and test system for proper operation.
Removal ("F" Body)
Discharge A/C system, using approved recovery/recycling
equipment. Disconnect negative battery cable. Disconnect A/C pressure
switch connector. Use a backup wrench to hold evaporator fitting, and
loosen evaporator liquid line fitting. Remove bolt. Disconnect
evaporator liquid line. Remove and discard "O" rings. Using needle-
nose pliers, remove orifice tube from evaporator inlet line.
Installation
1) Clean evaporator line fitting with refrigerant oil. Coat
inside of inlet line and evaporator line "O" rings with refrigerant
oil. Lubricate orifice tube and "O" ring with refrigerant oil and
insert them into inlet line. Insert orifice tube into evaporator inlet
line with long screen inlet end toward condenser.
2) Tighten bolt to 12 ft. lbs. (16 N.m). Tighten evaporator
line fitting to 28 ft. lbs. (38 N.m). To complete installation,
reverse removal procedure. Evacuate, charge, and test system for
proper operation.
Removal ("J" & "N" Body)
1) Locate orifice tube. See ORIFICE TUBE LOCATION &
REMOVER/INSTALLER APPLICATION table. Discharge A/C system, using
approved recovery/recycling equipment. On "J" body, remove upper
closeout panel. On "N" body, raise and support vehicle. On all models,
disconnect condenser-to-evaporator line at condenser outlet and
discard "O" rings.
2) Disconnect condenser-to-evaporator line clip on right side
body rail, behind engine mount. Remove orifice tube using Orifice Tube
Remover/Installer (J-26549-E) or needle-nose pliers.
3) If difficulty is encountered during removal of a plugged
or restricted orifice tube, remove as much residue as possible. Using
a heat gun, carefully apply heat 1/4" from dimples on condenser inlet
line. Be careful not to overheat line.
4) If A/C pressure switch is located near orifice tube,
remove switch to protect it from heat. While heat is being applied,
grip orifice tube using orifice tube remover/installer or needle-nose
pliers. Use a turning motion along with a push-pull motion to loosen
and remove orifice tube.
Installation
1) Coat inside of condenser inlet line and "O" rings with
refrigerant oil. Lubricate orifice tube "O" ring with refrigerant oil
and insert into condenser inlet line. Insert orifice tube into
condenser inlet line with shorter screen toward evaporator.
2) Connect condenser-to-evaporator line clip on right side
body rail. Lubricate "O" rings and connect condenser inlet line.
Tighten condenser inlet line nut to 12 ft. lbs. (16 N.m). Install
closeout panel. Evacuate, charge, and test system for proper
operation.
Removal ("W" Body)
1) Locate orifice tube. See ORIFICE TUBE LOCATION &
REMOVER/INSTALLER APPLICATION table. Remove air cleaner and duct
assembly. Discharge A/C system, using approved recovery/recycling
equipment. Disconnect negative battery cable. Disconnect ABS modulator
and A/C pressure sensor/fan switch electrical connectors.