air filter DODGE RAM 1999 Service Repair Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
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* A /C -H EA TE R S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES *
1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
A/C-Heater System Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Heating, Ventilation and Air Conditioning
ACCUMULATORS
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
AIR CONDITIONING FITTINGS
AIR CONDITIONING HOSES
AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES
AIR CONTROL DOORS
AIR DAMS (EXTERNAL)
AIR DISTRIBUTION SYSTEM
BELTS
BLEND DOORS
BLOWER FANS (BLOWER WHEEL OR SQUIRREL CAGE)
BLOWER MOTORS
BLOWER RESISTORS
BLOWER SWITCHES
CABIN AIR FILTERS
CIRCUIT BREAKERS
COMPRESSOR CLUTCH ASSEMBLIES
COMPRESSORS
CONDENSER AIR SEALS
CONDENSER FAN MOTORS
CONDENSERS
CONNECTORS
CONTROL CABLES
CONTROL HEADS (FUNCTION SELECTORS)
CONTROL LINKAGES
CONTROL MODULES
COOLANT
COOLING FAN BLADES
COOLING FAN CLUTCHES
COOLING FAN MOTORS
EVAPORATOR DRAIN TUBES
EVAPORATOR PRESSURE REGULATORS (EPRS)
EVAPORATORS
EXPANSION VALVES
FUNCTION SELECTORS
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSIBLE LINKS
GASKETS
HEATER CASES
HEATER CONTROL VALVES
HEATER CORES
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HEATER HOSES
HIGH PRESSURE RELIEF VALVES (HPRV)
IDLERS
IN-LINE FILTERS
METAL FITTINGS
METAL LINES
MIX AND AIR CONTROL DOORS (BLEND DOORS)
O-RINGS
ORIFICE TUBES
PILOT-OPERATED ABSOLUTES (POAS)
PLENUMS
PRESSURE CONTROL VALVES
PRESSURE SENSORS
PULLEYS
RADIATORS
RECEIVER-DRIERS
REFRIGERANT
REFRIGERANT OIL
RELAYS
SEALS
SERVICE PORTS
SPRING LOCK COUPLINGS
SUCTION THROTTLING VALVES (STVS)
SWITCHES (ELECTRICAL)
TENSIONERS
THERMISTORS AND PRESSURE SENSORS
THERMOSTATS AND HOUSINGS
VACUUM HOSES AND TUBES
VACUUM RESERVOIRS
VACUUM TUBES
VALVES IN RECEIVER (VIRS)
WATER PUMPS (ELECTRIC AUXILIARY)
WIRING HARNESSES AND CONNECTORS
MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
(1) a Pledge of Assurance to their Customers and (2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
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Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ (2) Require replacement.
Insulation overheated ... A ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.
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BLOWER SWITCHES
See SWITCHES.
CABIN AIR FILTERS
CABIN AIR FILTER INSPECTION \
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Condition Code Procedure
Air flow obstruction .... A ............. Require cleaning or
replacement.
Maintenance intervals ... 3 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
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CIRCUIT BREAKERS
See FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS .
COMPRESSOR CLUTCH ASSEMBLIES
COMPRESSOR CLUTCH ASSEMBLY INSPECTION \
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Condition Code Procedure
Air gap incorrect ....... B .. Require repair or replacement.
Bearing seized .......... A .. Require replacement of bearing
or assembly.
Bearing worn, affecting
performance ............ A .. Require replacement of bearing
or assembly.
Coil shows signs of
overheating ............ 1 .... Suggest replacement of coil.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted,
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(such as compression
fitting) ............... B ............ Require replacement.
Flange leaking .......... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Restricted internally ... A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
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EXPANSION VALVES
EXPANSION VALVE INSPECTION \
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Corroded internally ..... 1 ............ Suggest replacement.
Filter screen torn ...... A .. Require replacement of screen.
Inoperative ............. A ........... ( 1) Require repair or
replacement.
Leaking ................. A ............ Require replacement.
Restricted .............. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Expansion valve operation may be affected by capillary
tube location, corrosion, and insulation tape.
Inoperative includes intermittent operation.
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FUNCTION SELECTORS
See CONTROL HEADS (FUNCTION SELECTORS) .
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSE, FUSIBLE LINK AND CIRCUIT BREAKER INSPECTION \
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Blown ................... A ........ ( 1) Require replacement.
Corroded, affecting
performance ............ A .. Require repair or replacement.
Corroded, not affecting
performance ............ 2 .. Suggest repair or replacement.
Cracked, affecting
performance ............ A .. Require repair or replacement.
Cracked, not affecting
performance ............ 1 .. Suggest repair or replacement.
Inoperative ............. A ... ( 2) Require replacement.
Insulation damaged,
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Melted .................. 1 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Outer covering damaged .. 1 ............ Suggest replacement.
Outer covering damaged to
the extent that the inner
fabric is visible ...... A ............ Require replacement.
Protective sleeves
damaged ................ 2 . Suggest replacement of sleeves.
Protective sleeves
missing ................ 2 . Suggest replacement of sleeves.
Restricted, affecting
performance ............ A .. Require repair or replacement.
Restricted, not affecting
performance ............ 2 .. Suggest repair or replacement.
Routed incorrectly ...... 2 ................. Suggest repair.
Safety clip missing ..... C ............ Require replacement.
Spongy .................. 1 .. Suggest repair or replacement.
Stripped ................ A ............ Require replacement.
Surface cracks (dry-
rotted) ................ 1 .. Suggest repair or replacement.
Swollen ................. B ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Type incorrect .......... 1 .. Suggest repair or replacement.
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HIGH PRESSURE RELIEF VALVES (HPRV)
HIGH PRESSURE RELIEF VALVE (HPRV) INSPECTION \
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Condition Code Procedure
Inoperative ............. A ........... ( 1) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Inoperative includes intermittent operation or out of
OEM specification.
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IDLERS
See TENSIONERS.
IN-LINE FILTERS
IN-LINE FILTER INSPECTION \
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Condition Code Procedure
Connection leaking ...... B .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Restricted .............. A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
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METAL FITTINGS
See
AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES .
METAL LINES
See
AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES .
MIX AND AIR CONTROL DOORS (BLEND DOORS)
See PLENUMS.
O-RINGS
O-RING INSPECTION \
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Condition Code Procedure
Leaking ................. A ........... ( 1) Require repair or
replacement.
( 1) - Require inspection of mating and sealing surface and
repair or replace as necessary.
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ORIFICE TUBES
ORIFICE TUBE INSPECTION \
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Bypassing internally .... A .. Require repair or replacement.
Filter screen torn ...... A ............ Require replacement.
Installation incorrect .. B ................. Require repair.
Restricted .............. A .. Require repair or replacement.
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PILOT-OPERATED ABSOLUTES (POAS)
PILOT-OPERATED ABSOLUTE (POA) INSPECTION \
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Condition Code Procedure
Connection damaged ...... B .. Require repair or replacement.
Fitting damaged ......... B .. Require repair or replacement.
Inoperative ............. A ........... ( 1) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Inoperative includes intermittent operation or out of
OEM specification.
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PLENUMS
PLENUM INSPECTION
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Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket holes elongated,
affecting performance .. A .. Require repair or replacement.
Bracket holes elongated,
not affecting
performance ............ .. ........ No service suggested or
required.
Bracket loose, affecting
performance ............ A .. Require repair or replacement.
Bracket loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket missing ......... C ............ Require replacement.
Connection damaged ...... B .. Require repair or replacement.
Contaminated, affecting
performance ............ A ............ Require replacement.
Corroded internally ..... 1 ............ Suggest replacement.
Dessicant bag
deteriorated ........... A ........ (1) Require replacement.
Further inspection required.
Dessicant at the end of
its useful life
(saturated
with moisture) ......... 1 .. Suggest repair or replacement.
Filter screen torn ...... A .. Require replacement of screen.
Fitting damaged ......... B .. Require repair or replacement.
Fusible plug leaking .... A .... Require replacement of plug.
Inoperative ............. A ........... ( 2) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Pressure relief device
leaking ................ A . Require replacement of pressure
relief device.
Restricted .............. A .. Require repair or replacement.
Sight glass no longer
transparent ............ 2 ... Suggest replacement of drier.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Tubing connection
leaking ................ A .. Require repair or replacement.
( 1) - Inspect system to determine effects of dessicant bag
deterioration.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.
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WATER PUMPS (ELECTRIC AUXILIARY)
WATER PUMP (ELECTRIC AUXILIARY) INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
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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\
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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.
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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.
Page 158 of 1691
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