DODGE RAM 1999 Service Repair Manual

2) Disconnect liquid line/suction line bracket. Disconnect
liquid line at orifice tube. Remove orifice tube using specified
orifice tube remover/installer. See ORIFICE TUBE LOCATION &
REMOVER/INSTALLER APPLICATION table.
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 heat inlet line. If inlet line has small
dimples, apply heat 1/4" from dimples. 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 needle-nose pliers. Use a turning motion along
with a push-pull motion to loosen and remove orifice tube.
Installation
1) Coat inside of inlet line and "O" ring 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 short screen toward condenser.
2) Tighten liquid line fitting at orifice tube to 20 ft. lbs.
(27 N.m). To complete installation, reverse removal procedure.
Evacuate, charge, and test system for proper operation.
Removal ("C" & "K" Series)
1) Discharge A/C system, using approved recovery/recycling
equipment. On models equipped with front A/C system only, remove front
grille. Using a backup wrench, loosen condenser-to-evaporator (liquid)\
line fitting at condenser and disconnect line.
2) On models equipped with rear A/C system, loosen condenser-
to-evaporator (liquid) line fitting between junction block and
evaporator. If necessary, remove air cleaner assembly.
3) On all models, remove and discard fitting "O" ring. Using
Orifice Tube Remover/Installer (J-26549-E), remove orifice tube from
liquid line. If difficulty is encountered during removal of a plugged
or restricted orifice tube, remove as much residue as possible.
4) Using a heat gun, carefully apply heat 1/4" from dimples
on liquid line. Be careful not to overheat line. If A/C pressure
switch is located near orifice tube, remove switch to protect it from
heat.
5) While heat is being applied, grip orifice tube using
orifice tube remover/installer. Use a turning motion along with a
push-pull motion to loosen and remove orifice tube.
Installation
1) Clean liquid line fitting with refrigerant oil. Coat
inside of liquid line and "O" ring with refrigerant oil. Lubricate
orifice tube and "O" ring with refrigerant oil and insert them into
liquid line. Insert longer orifice tube screen (inlet end) into
condenser outlet line first, toward condenser.
2) Tighten liquid line fitting to 18 ft. lbs. (24 N.m). To
complete installation, reverse removal procedure. Evacuate, charge,
and test system for proper operation.
Removal ("G", "L" & "M" Series)
1) Discharge A/C system, using approved recovery/recycling
equipment. Using a backup wrench, loosen evaporator inlet (liquid)
line fitting at evaporator. Disconnect inlet line. Remove and discard
"O" ring(s). Using Orifice Tube Remover/Installer (J-26549-E), remov\
e
orifice tube from liquid line.
2) 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 liquid line. Be
careful not to overheat line.

3) 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. Use a turning
motion along with a push-pull motion to loosen and remove orifice
tube.
Installation
1) Clean liquid line fitting with refrigerant oil. Add one
ounce of refrigerant oil to system. Coat inside of liquid line and "O"
rings with refrigerant oil. Lubricate orifice tube and "O" ring with
refrigerant oil and insert them into liquid line. Insert shorter
orifice tube screen into liquid line first with long screen (inlet
end) toward condenser.
2) Tighten liquid line fitting to 20 ft. lbs. (27 N.m). To
complete installation, reverse removal procedure. Evacuate, charge,
and test system for proper operation.
Removal ("U" Series)
1) Remove air cleaner and duct assembly. Discharge A/C
system, using approved recovery/recycling equipment. Using a backup
wrench, loosen condenser outlet (liquid) line fitting at orifice tube.\
Disconnect liquid line. Remove and discard "O" rings. Using needle-
nose pliers, remove orifice tube from liquid line.
2) 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 liquid line. Be
careful not to overheat line.
3) 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 needle-nose pliers. Use a turning motion along
with a push-pull motion to loosen and remove orifice tube.
Installation
1) Clean liquid line fitting with refrigerant oil. Add one
ounce of refrigerant oil to system. Coat inside of liquid line and "O"
rings with refrigerant oil. Lubricate orifice tube and "O" ring with
refrigerant oil and insert them into liquid line. Insert orifice tube
into liquid line with long screen (inlet end) toward condenser.
2) Tighten liquid line fitting to 20 ft. lbs. (27 N.m). To
complete installation, reverse removal procedure. Evacuate, charge,
and test system for proper operation.
ORIFICE TUBE LOCATION & REMOVER/INSTALLER APPLICATION









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Application Orifice Tube Orifice Tube
Location Remover/Installer
Cars
"C" Body ...................... ( 1) .................. J-26549-D
"E" & "K" Body ................ ( 1) .................. J-26549-D
"F" Body .............. Evaporator Inlet .. ....................
"G" Body .............. Evaporator Inlet ............. J-26549-E
"H" Body .............. Condenser Outlet ............. J-26549-D
"J" Body .............. Condenser Outlet ............. J-26549-E
"N" Body ( 2) .......... Condenser Outlet ............. J-26549-E
"W" Body ...................... ( 3) .................. J-26549-E
Trucks & Vans
"C" & "K" Series
With Rear A/C ........ Evaporator Inlet ............. J-26549-E
Without Rear A/C ..... Condenser Outlet ............. J-26549-E
"G" Series ............ Evaporator Inlet ............. J-26549-E
"L" & "M" Series ...... Evaporator Inlet ............. J-26549-E
"S" & "T" Series ...... Evaporator Inlet ............. J-26549-D

"U" Series ............ Condenser Outlet ................... N/A
(1) - In evaporator (liquid) inlet line, between service valves, above
accumulator.
( 2) - Cutlass and Malibu only.
( 3) - In evaporator (liquid) inlet line, between high-side service
valve and evaporator.









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JEEP
NOTE: On Cherokee and Grand Cherokee, fixed orifice tube is located
in the liquid line. If the fixed orifice tube is faulty or
plugged, the liquid line and orifice tube must be replaced as
an assembly.
Removal & Installation (Cherokee & Grand Cherokee)
Disconnect battery negative cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
liquid line retaining clips. Disconnect liquid line from evaporator
inlet and condenser outlet tubes. Cover open refrigerant fittings to
protect from moisture and dirt. 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.
Removal & Installation (Wrangler)
1) Disconnect battery negative 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 needle nose pliers, remove fixed orifice tube from
condenser outlet tube. Note fixed orifice tube orientation for correct
installation. 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.
REFRIGERANT RECOVERY/RECYCLING
Refrigerant recovery/recycling equipment is used to remove
refrigerant from vehicle's A/C system without polluting atmosphere. To
remove and recycle refrigerant, ALWAYS follow instructions provided
with the refrigerant recovery/recycling equipment being used.
The removed refrigerant is filtered, dried and stored in a
tank within the recovery/recycling equipment until it is ready to be
pumped back into the vehicle's A/C system.
NOTE: Separate sets of hoses, manifold gauge set and refrigerant
recovery/recycling equipment MUST be used for R-12 and R-134a
systems. DO NOT mix R-12 and R-134a refrigerants, as their
refrigerant oils and desiccants are NOT compatible.
CHRYSLER CORP.
Manufacturer recommends using refrigerant recovery/recycling
equipment which meets SAE standard J1991 or J2210. Always follow
instructions provided with the recovery/recycling equipment being
used.
FORD MOTOR CO.
1) Connect hoses from Recovery/Recycling/Charging Center
(023-00150) to high-side and low-side service valves. See SERVICE

VALVE LOCATIONS under SYSTEM SERVICE VALVES.
2) Turn equipment on and recover refrigerant according to
equipment manufacturer's operating instructions. Allow equipment to
operate until refrigerant is recovered. Close inlet valve (if
equipped) on refrigerant recovery/recycling/charging center and turn
equipment off.
NOTE: On some applications, refrigerant recovery/recycling/charging
center will automatically shut off through the use of a low
pressure switch. On other applications, refrigerant
recovery/recycling/charging center must be manually shut
off.
3) Allow A/C system to remain closed for about 2 minutes
while observing vacuum pressure readings. If vacuum pressure reading
increases, repeat step 2) until vacuum pressure readings remain stable
for 2 minutes. If vacuum pressure readings remain stable for 2
minutes, disconnect hoses from service ports and perform required A/C
system repairs.
GENERAL MOTORS
Manufacturer recommends using A/C Refrigerant Recovery,
Recycling And Recharging (ACR4) System (J-39500). The ACR4 system ha\
s
one filtering cycle during recovery plus an automatic multiple pass
filtering during evacuation cycle. Follow manufacturer's instructions
provided with ACR4 equipment being used.
JEEP
Manufacturer recommends using refrigerant recovery/recycling
equipment which meets SAE standard J1991 or J2210. Always follow
instructions provided with the recovery/recycling equipment being
used.
FLUSHING A/C SYSTEM
There is considerable controversy over the question of
whether or not to flush A/C systems or how to go about it. Before CFCs
were classified as harmful to the environment, it was a common
practice to open flush contaminants from a system. The waste fluid was
vented to the atmosphere. This practice is now ILLEGAL and can no
longer be used.
Most OEMs don't recommend A/C system flushing. They recommend
replacing the defective component and installing a liquid line (in-
line) filter ahead of the expansion valve or orifice tube. Ford Motor
Company is one exception to this rule.
CHRYSLER CORP.
Information is not available from manufacturer.
FORD MOTOR CO.
NOTE: DO NOT flush accumulator/receiver-drier, muffler, hoses and
thermal expansion valve/fixed orifice tube as residual
flushing agent cannot be completely removed from these
components. These components are generally replaced after A/C
system contamination. Hoses can be reused, unless they are
clogged with debris. Only flush evaporator core and condenser
core, and metal inlet and outlet lines.

1) Manufacturer recommends flushing contaminated system using
one gallon of Ford A/C System Flushing Solvent (F4AZ-19579-A), a
Filter (FL-1A), an A/C Flusher Fitting Kit (014-00992). DO NOT reuse\
flushing solvent and filter, they are intended to be used on one
vehicle only.
2) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Flush specified A/C components using A/C
System Flusher (014-00991), according to manufacturer's operating
instructions.
3) If an A/C system flusher is not available to clean A/C
system, an in-line filter kit can be used. Filter kit is installed
before replacement compressor, accumulator/receiver-drier, muffler,
and thermal expansion valve/fixed orifice tube have been installed.
4) Filter kits are used with either a rubber lined suction
hose or with a nylon lined suction hose located between compressor and
evaporator. Rubber lined hose has a wall thickness of 1/4" and nylon
lined hose has a wall thickness of 1/8". See Fig. 22.
5) The filter kit for either type hose has 2 filters. A
temporary pancake filter and a permanent in-line suction filter.
Pancake filter is temporarily installed between condenser and
condenser-to-evaporator line. See Fig. 23. Permanent filter is
installed in suction line between accumulator and compressor.
6) Install replacement components (compressor, accumulator
and fixed orifice) with correct amount of refrigerant oil. See
COMPRESSOR REFRIGERANT OIL CHECKING article.
7) Cut suction hose between compressor and accumulator
(closer to compressor). Remove a length of suction hose to accommodate\
suction filter. Measure side wall of suction hose and install
appropriate filter with "O" rings and filter clamps. If side wall is
1/4", use in-line filter labeled USE WITH RUBBER INNER LINED HOSE. If
side wall is 1/8", use in-line filter labeled USE WITH NYLON INNER
LINED HOSE. Ensure arrow on filter is pointing in direction of
refrigerant flow. Tighten hose clamps to 54 INCH lbs. (6 N.m). See
Fig. 22 .
8) Install pancake filter in liquid line between condenser
and condenser-to-evaporator line. Ensure filter inlet (label) is
toward condenser. Evacuate, charge, and leak test A/C system. See
EVACUATING A/C SYSTEM, CHARGING A/C SYSTEM and LEAK TESTING. Check
filters and hoses for clearance from other engine components. Use tie
straps if necessary.
9) Place an external cooling fan in front of radiator. Select
MAX A/C operation and set blower motor speed to maximum. Start engine
and allow to idle. Ensure A/C is operating properly. Slowly increase
engine speed to 800 RPM, then 1000 RPM, and then to 1200 RPM. With
engine speed set to 1200 RPM, operate engine for one hour with A/C
system operating.
10) Stop engine. Discharge A/C system, using approved
refrigerant recovery/recycling equipment. Remove pancake filter, hoses
and fittings. Discard pancake filter. Reconnect liquid line, evacuate,
charge, and leak test A/C system. Ensure A/C system is operating
properly.

Fig. 22: Permanent A/C System Filters
Courtesy of ford motor co.

Fig. 23: Temporary Pancake Filter
Courtesy of ford motor co.
GENERAL MOTORS
Information is not available from manufacturer.
JEEP
Information is not available from manufacturer.
EVACUATING A/C SYSTEM
CAUTION: DO NOT operate A/C compressor during evacuation procedure or
with vacuum applied to A/C system. Compressor may be
damaged.
CHRYSLER CORP.
Avenger 2.0L & Sebring Coupe 2.0L
1) Ensure all manifold gauge set valves are closed. Connect
manifold gauge set service valves. Connect vacuum pump adapter to
vacuum pump. Connect manifold gauge set Yellow hose to vacuum pump
adapter.
2) Fully open manifold gauge set low-pressure valve and
adapter valve, and start vacuum pump. Operate vacuum pump for about 10
minutes until low-side vacuum reading is 29.5 in. Hg or more. Turn
vacuum pump off and observe vacuum gauge.
3) If A/C system maintains specified vacuum for 5 minutes,
system is okay. If A/C system cannot get to or maintain specified
vacuum for 5 minutes, ensure connections are tight and repeat
evacuation. If A/C system still does not maintain specified vacuum,
check for defective vacuum pump or leak in A/C system or gauge set.
See LEAK TESTING. Repair or replace components as necessary.

Avenger 2.5L & Sebring Coupe 2.5L
Connect approved recovery/recycling equipment to vehicle.
Evacuate A/C system using recovery/recycling equipment according to
manufacturer's instructions.
Dakota, Durango, Ram Pickup & Ram Van/Wagon
1) Connect approved recovery/recycling equipment and manifold
gauge set. Fully open manifold gauge set low-side and high-side
valves, and start vacuum pump. Operate vacuum pump until low-side
vacuum reading of 26 in. Hg or more. Close all valves and turn vacuum
pump off. Observe vacuum gauge and go to next step.
2) If A/C system maintains specified vacuum for 5 minutes,
restart vacuum pump, open low-side and high-side valves, and evacuate
system for an additional 10 minutes. Close all valves. Turn vacuum
pump off and disconnect pump.
3) If A/C system cannot get to or maintain specified vacuum,
check for a defective vacuum pump or a leak in A/C system or gauge
set. See LEAK TESTING. Repair or replace components as necessary.
All Other Models
1) Connect approved recovery/recycling equipment and manifold
gauge set to vacuum pump. Fully open manifold gauge set suction and
discharge valves, and start vacuum pump. Operate vacuum pump at least
45 minutes with a low-side vacuum reading of 26 in. Hg or more (28 in.
Hg or more on Neon). Close all valves. Turn vacuum pump off and
observe vacuum gauge.
2) If A/C system maintains specified vacuum for 30 minutes,
open all valves, start vacuum pump and operate for an additional 10
minutes. Close all valves. Turn vacuum pump off and disconnect pump.
If A/C system cannot get to or maintain specified vacuum for 30
minutes, check for a defective vacuum pump or leak in A/C system or
gauge set. See LEAK TESTING. Repair or replace A/C system components
as necessary.
FORD MOTOR CO.
1) If using approved Recovery/Recycling/Charging Center (023-\
00150) connect to high-side and low-side service valves. See SERVICE
VALVE LOCATIONS under SYSTEM SERVICE VALVES. Connect manifold gauge
set center hose to vacuum pump.
2) Open both valves on manifold gauge set. Operate vacuum
pump until low-side vacuum reading is at least 29.5 in. Hg (as close
to 30 in. Hg as possible). Operate vacuum pump for at least 45
minutes.
3) Close both valves on manifold gauge set. Turn off vacuum
pump. Observe low-side gauge. Any loss of vacuum in 5 minutes
indicates a system leak. Perform leak testing procedure. See LEAK
TESTING. Repair system as necessary and repeat evacuation procedure.
GENERAL MOTORS
Manufacturer recommends using A/C Refrigerant Recovery,
Recycling And Recharging (ACR4) System (J-39500). The ACR4 system ha\
s
one filtering cycle during recovery plus an automatic multiple pass
filtering during evacuation cycle. Follow manufacturer's instructions
provided with ACR4 equipment being used.
JEEP
1) Connect approved recovery/recycling equipment and manifold
gauge set. Fully open manifold gauge set low-side and high-side
valves, and start vacuum pump. Operate vacuum pump until low-side

vacuum reading of 26 in. Hg or more. Close all valves and turn vacuum
pump off. Observe vacuum gauge, go to next step.
2) If A/C system maintains specified vacuum for 5 minutes,
open low-side and high-side valves, restart vacuum pump and operate
for an additional 10 minutes. Close all valves. Turn vacuum pump off
and disconnect pump.
3) If A/C system cannot get to or maintain specified vacuum,
check for a defective vacuum pump or leak in A/C system or gauge set.
See LEAK TESTING. Repair or replace components as necessary.
CHARGING A/C SYSTEM
* PLEASE READ THIS FIRST *
CAUTION: During charging of A/C system, refrigerant container must be
in an upright position. If refrigerant container is
upside down, compressor may be damaged by liquid refrigerant
drawn into A/C system.
CHRYSLER CORP.
Avenger 2.0L & Sebring Coupe 2.0L
1) Ensure A/C system has no leaks and has been evacuated. See
EVACUATING A/C SYSTEM and LEAK TESTING. Locate sight glass on
receiver-drier and ensure it is clean. Close low-pressure adapter
valve and remove from manifold gauge set.
2) Connect low-pressure adapter valve to refrigerant
container and open container valve. Ensure Blue charging hose is
properly connected to vehicle low-pressure service valve. Open adapter
valve.
3) If refrigerant is not drawn in, fully close adapter valve
and check for hose connection leaks. If leak is detected, retighten
connections and repeat A/C system evacuation. See EVACUATING A/C
SYSTEM.
4) If refrigerant is drawn in, start engine. Turn A/C on and
set temperature control to maximum cold and blower motor to low speed.
Operate engine at 1500 RPM. As refrigerant is drawn into system, foam
or bubbles will appear in sight glass.
5) System charge will be close to full when sight glass is
clear, compressor clutch is engaged, and compressor suction and
discharge line temperatures are similar. System charge will be
complete when sight glass is clear, compressor clutch is engaged,
compressor discharge line is warm and suction line is cool.
6) When proper amount of refrigerant has been added, stop
engine. Close refrigerant container and adapter valve, and disconnect
gauge set.
Breeze, Cirrus, Concorde, Intrepid, LHS, Stratus & 300M (Scan
Tool Method)
1) Attach Diagnostic Readout Box (DRB) to Data Link Connecto\
r
(DLC). Set DRB (scan tool) to PARTIAL CHARGE TEST. Attach clamp-on
Thermocouple (80PK-1A) to liquid line, as close to condenser outlet as\
possible.
2) Set parking brake, and place transaxle in Park position.
Start engine and allow to idle. Set A/C controls to outside air, panel
mode, full cool, and high blower speed. Turn A/C on, and open vehicle
windows. Operate A/C system for a few minutes to allow system to
stabilize.
3) Place cardboard over front grille area, to block airflow
through part of condenser, to set A/C system pressure to 260 psi (18.3
kg/cm
). This will stop cooling fans from alternating speeds and
maintain constant pressure.

4) Scan tool will automatically calculate system charge.
Depending on system charge condition, corrections are made 2 ounces at
a time. Each time a correction is made, recheck readings to ensure
proper charge. For system refrigerant capacity, see REFRIGERANT OIL &
REFRIGERANT SPECIFICATIONS article.
Breeze, Cirrus, Concorde, Intrepid, LHS, Stratus & 300M
(Manifold Gauge Set Method)
1) Attach clamp-on Thermocouple (80PK-1A) to liquid line, as\
close to condenser outlet as possible. Attach manifold gauge set to
vehicle.
2) Set parking brake, and place transaxle in Park position.
Start engine and allow to idle. Set A/C controls to outside air, panel
mode, full cool, and high blower speed. Turn A/C on, and open windows.
Operate system for a few minutes to allow system to stabilize.
3) Place cardboard over front grille area, to block airflow
through part of condenser, to set A/C pressure to 260 psi (18.3
kg/cm
). This will stop cooling fans from alternating speeds and
maintain constant pressure.
4) Record temperature reading at liquid line and discharge
pressure reading on gauges. Compare readings with values in
REFRIGERANT CHARGE LEVEL table.
5) Depending on system charge condition, corrections are made
2 ounces at a time. Each time a correction is made, recheck readings
to ensure proper charge. For system refrigerant capacity, see
REFRIGERANT OIL & REFRIGERANT SPECIFICATIONS article.
REFRIGERANT CHARGE LEVEL









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Liquid Line Temp. ( 1) Discharge PressureF (C) psi (kg/cm)
40 (4.4) ........................................... 53-75 (3.7-5.3\
)
60 (15.6) ......................................... 81-104 (5.7-7.3\
)
80 (26.7) ....................................... 111-142 (7.8-10.0\
)
100 (37.8) ..................................... 156-194 (11.0-13.6\
)
120 (48.9) ..................................... 208-259 (14.6-18.2\
)
140 (60.0) ..................................... 272-331 (19.1-23.3\
)
160 (71.1) ..................................... 353-420 (24.8-29.5\
)
180 (82.2) ..................................... 447-516 (31.4-36.3\
)
( 1) - When pressure is lower than specified, system is undercharged.
When pressure is higher than specified, system is overcharged.









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All Other Models
Ensure A/C system has been checked for leaks and evacuated.
See EVACUATING A/C SYSTEM and LEAK TESTING. Charge A/C system to
specifications. For system refrigerant capacity, see REFRIGERANT OIL &
REFRIGERANT SPECIFICATIONS article.
FORD MOTOR CO.
1) If using approved Recovery/Recycling/Charging Center (023-\
00105 or 023-00150), connect to high-side and low-side service valves.
See SERVICE VALVE LOCATIONS under SYSTEM SERVICE VALVES. Operate
charging center according to manufacturer's instructions. Charge
system with specified amount of refrigerant and refrigerant oil. See
REFRIGERANT OIL & REFRIGERANT SPECIFICATIONS article. Check amount of
refrigerant oil in system before adding oil. See COMPRESSOR
REFRIGERANT OIL CHECKING article.
2) If using manifold gauge set, connect to high-side and low-
side service valves. See SERVICE VALVE LOCATIONS under SYSTEM SERVICE