charging 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
Page 3 of 1691
"C" ABBREVIATION TABLE (con’t)
ABBREVIATION DEFINITION CKT Circuit CLR Clear CNG Compressed Natural Gas CO Carbon Monoxide CO2 Carbon Dioxide CONV Convertible CP Canister Purge CPA Connector Position Assurance CPS Crank Position Sensor CTS Coolant Temperature Sensor CV Check Valve Constant Velocity CVC Constant Vacuum Control CW Clockwise CYL Cylinder Calif. California Carb. Carburetor Chrg. Charging Circ. Circuit Cntrl. Control Comp. Compressor or Compartment Conn. Connector Cont. Continued Conv. Convertible or Converter Cu. In. Cubic Inch Cyl. Cylinder
"D" ABBREVIATION TABLE
"D" ABBREVIATION TABLE
ABBREVIATION DEFINITION "D" Drive DBC Dual Bed Catalyst DC Direct Current or Discharge DDD Dual Diaphragm Distributor DERM Diagnostic Energy Reserve Module DFI Digital Fuel Injection DIC Driver Information Center DIS Direct Ignition System DIS Distributorless Ignition System DIST Distribution DISTR Distributor DK BLU Dark Blue DK GRN Dark Green DME Digital Motor Electronics (Motronic
System) DOHC Double Overhead Cam DOT Department of Transportation DP Dashpot DRB-II Diagnostic Readout Box DVOM Digital Volt/Ohm Meter (see VOM) Def. Defogger or Defroster Def. Defrost Defog. Defogger Diag. Diagnostic Dist. Distributor or Distribution Dr. Door
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Use only NEW, moisture-free refrigerant oil in A/C systems.
Refrigerant oil is highly refined with a very low moisture content.
Oil container must be tightly closed when not in use, or moisture from
air will be absorbed into refrigerant oil.
Refrigerant R-134a systems use Polyalkylene Glycol (PAG)
refrigerant oil. Using a mineral oil based lubricant with R-134a
systems will result in A/C compressor failure due to lack of proper
lubrication.
All compressors have different lubrication requirements and
use different Polyalkylene Glycol (PAG) refrigerant oils. Use only the\
specified PAG refrigerant oil for the appropriate system and A/C
compressor. Always check the underhood A/C specification label or A/C
compressor label before adding refrigerant oil to A/C
compressor/system. See listing of refrigerant oils currently available
from the vehicle manufacturers.
NOTE: PAG oil absorbs moisture very rapidly, 2.3-5.6 percent by
weight as compared to a mineral oil absorption rate of .005
percent by weight.
CHRYSLER CORP., JEEP & EAGLE
Use ND-8 PAG oil, SUN PAG 56 oil, SP-10 PAG oil, or SP-20 PAG
oil.
FORD MOTOR CO.
Use YN-12B or YN-12C PAG Refrigerant Oil (specification WSH-
M1C231-B) or SP-20 PAG Oil (specification WST-M1C231-B2).
GENERAL MOTORS
On all models except Saturn, use PAG Refrigerant Oil (Part
No. 12345923). On Saturn, use Saturn PAG refrigerant oil.
SERVICING PRECAUTIONS
DISCHARGING SYSTEM
Discharge A/C system, using approved refrigerant
recovery/recycling equipment before loosening any fittings. Follow
refrigerant recovery/recycling equipment manufacturer's instructions.
DISCONNECTING LINES & FITTINGS
After system is discharged, carefully clean area around all
fittings to be opened. Always use 2 wrenches when loosening or
tightening fittings. Some refrigerant lines are connected with a
spring-lock coupling. Special tools may be required to disconnect
lines. To prevent dirt and moisture from entering system, cap all
openings as soon as lines are removed. DO NOT remove service valve
caps until ready to connect lines and fittings.
NOTE: All R-134a based systems use 1/2-16 ACME threaded fittings.
Ensure all replacement parts match the connections of the
system being worked on.
CONNECTING LINES & FITTINGS
Always use new a gasket or "O" rings when connecting lines or
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CLUTCH ASSEMBLY
Removal (Except Grand Cherokee)
Remove compressor shaft bolt. Remove clutch plate and shims.
Tighten a 10-mm bolt into clutch hub bolt hole to remove clutch hub
and shims. Remove snap ring, and remove rotor and pulley assembly.
Remove snap ring, and disconnect clutch coil lead. Remove clutch coil.
Installation
1) Install clutch coil so pin in back of coil aligns with
hole in front compressor housing. Connect clutch coil lead. Install
snap ring with bevel side facing outward. Ensure snap ring is properly
seated in groove. Install rotor and pulley assembly. Install shims and
snap ring. Install clutch hub.
2) Install dial indicator at front of clutch hub to measure
clutch hub air gap. Using battery voltage, energize clutch coil.
Proper air gap is 0.014-0.026" (0.35-0.65 mm). Add or remove shims to
obtain correct air gap. Install compressor shaft bolt. On Concord and
Intrepid, tighten compressor shaft bolt to 11-15 ft. lbs. (15-20 N.m).\
On all other models, tighten compressor shaft bolt to 10 ft. lbs. (14
N.m).
NOTE: On Grand Cherokee, compressor clutch can be serviced in
vehicle without discharging A/C system.
Removal (Grand Cherokee)
Disconnect and isolate negative battery cable. Remove
serpentine drive belt. Remove compressor shaft bolt. Using a plastic
mallet, tap clutch plate to loosen from compressor shaft. Remove
clutch plate, shaft key and shims. See Fig. 5. Remove snap ring, and
remove pulley assembly. Remove snap ring, and disconnect clutch coil
lead. Remove clutch coil.
Installation
1) Install clutch coil so pin in back of coil aligns with
hole in front compressor housing. Connect clutch coil lead. Install
snap ring with bevel side facing outward. Ensure snap ring is properly
seated in groove. Align snap ring eyelets to the left or right of
clutch coil pin. Install rotor and pulley assembly. Install shims and
snap ring. Install clutch hub.
2) Hold clutch plate tight against shims and measure air gap
between clutch plate and pulley face. Air gap should be 0.014-0.026"
(0.35-0.65 mm). Add or remove shims as necessary. Install compressor
shaft bolt. Tighten compressor shaft bolt to 115 INCH lbs. (13 N.m).
To complete installation, reverse removal procedure.
3) After completing compressor clutch installation, start
engine. Set A/C-heater control to recirculated air mode and high
blower motor speed. Set engine speed to 1500-2000 RPM. Cycle
compressor on for 5 seconds and off for 5 seconds, about 20 times to
break-in clutch.
SHAFT SEAL
NOTE: Shaft seal replacement procedure is for 10PA17C compressor.
Shaft seal replacement procedure for 10PA17 compressor is not
available.
Removal
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove A/C compressor. Drain oil from
compressor, and measure amount drained. Remove clutch hub, shims,
rotor and pulley assembly, and clutch coil. See CLUTCH ASSEMBLY. See
Page 38 of 1691
Fig. 6: Compressor Components (Sanden MSC90-C Scroll)
Courtesy of chrysler corp.
SANDEN SD-7H15 7-CYLINDER
NOTE: On Cherokee, Dakota, Durango, Ram Pickup and Wrangler,
compressor clutch can be serviced in vehicle, without
discharging A/C system.
CLUTCH ASSEMBLY
Removal (Cherokee, Dakota, Durango, Ram Pickup & Wrangler)
1) Disconnect and isolate negative battery cable. Remove
serpentine drive belt. Disconnect clutch coil harness connector.
Without disconnecting refrigerant lines, remove A/C compressor from
mounting bracket. Support compressor in engine compartment.
2) Using spanner wrench, hold clutch plate and remove
compressor shaft nut. See Fig. 1. Using a steering wheel puller,
remove clutch plate, compressor shaft key and shims. Remove external
front housing snap ring.
3) Install jaws of Rotor Puller (C-6141-1) into pulley snap
ring groove. Install Shaft Protector (C-6141-2) over compressor shaft.\
Install puller flange plate on jaws. Install Puller Through-Bolts (C-
6461) through puller flange plate into jaws and hand tighten. Tighten
pulley center bolt clockwise and remove pulley from compressor.
4) Remove clutch coil wire harness retainer from compressor
housing. Remove clutch coil snap ring and clutch coil.
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5) Remove clutch coil wire harness retainer from compressor
housing. Remove clutch coil snap ring and clutch coil.
Installation (Ford "F" Series Super Duty Pickup)
1) Install clutch coil and clutch coil snap ring. Install
clutch coil wire harness to compressor housing. Align pulley and
bearing assembly on front compressor housing hub.
2) Install pulley installer handle and driver into pulley
assembly bearing cavity. Ensure outer edge of driver rests firmly on
inner race of bearing. Using hammer, install pulley and bearing
assembly. While tapping on handle, guide pulley and bearing assembly
to prevent binding. Ensure pulley assembly bottoms against compressor
housing.
3) Install internal bearing and external front housing snap
rings. Install original shim(s) and compressor shaft key. Using a
hammer and shaft protector, install clutch plate on compressor shaft.
Ensure clutch plate bottoms out on clutch shims. Replace compressor
shaft nut and tighten compressor shaft nut to 25-30 ft. lbs. (34-41 N.
m).
4) Measure air gap between clutch plate and pulley assembly
in 3 locations spaced equally around pulley. Rotate clutch pulley 180
degrees and check air gap as specified. Air gap should be 0.016-0.031"
(0.41-0.79 mm). If air gap is not within specification, adjust shim
thickness as necessary. To complete installation, reverse removal
procedure. Evacuate, charge, and leak test A/C system.
SANDEN TRS-90 & TR-105 SCROLL
CLUTCH ASSEMBLY
Removal
1) Without discharging A/C system, remove compressor from
mount. Install two 6-mm bolts in holes of clutch plate. Use 6-mm bolts
and 2 box-end wrenches to hold clutch plate while removing nut from
end of compressor shaft.
2) Remove clutch plate and shims. Using a plastic hammer, tap
clutch plate to loosen from compressor (if necessary). DO NOT pry
between clutch plate and pulley to remove clutch plate.
3) Remove pulley assembly snap ring. Remove pulley assembly.
Disconnect clutch coil lead. Scribe marks on clutch coil and
compressor for installation reference. Remove snap ring and clutch
coil.
NOTE: Rotor/pulley assembly and clutch plate are a matched pair and
should be replaced together.
Installation
1) Install clutch coil on compressor so locating pin engages
locating indentation. Install snap ring with beveled side away from
compressor. Secure clutch coil lead to compressor front cover and
connect lead to thermal limiter switch.
2) Install pulley assembly. Install snap ring with beveled
side away from compressor. If reusing original clutch plate and
pulley, old shims can be used.
3) If new components are used, install several shims so shim
pack thickness is 0.10" (2.5 mm). Align machined match marks and
install clutch plate and hold it tightly against shims.
4) Measure air gap between clutch plate and pulley surface.
Air gap should be 0.013-0.025" (0.33-0.64 mm). Adjust shim thickness
as necessary. On TRS-90, tighten compressor shaft nut to 13 ft. lbs.
(18 N.m). On TR-105, tighten compressor shaft nut to 10 ft. lbs. (14
N.m).
Page 41 of 1691
5) Once compressor shaft nut is tightened, check air gap
between clutch plate and pulley surface in at least 4 places. Readjust
air gap if necessary. Install A/C compressor. Evacuate and charge
system. Perform leak test. Ensure A/C system is operating properly.
6) After completing compressor clutch installation, start
engine. Set A/C-heater control to recirculated air mode and high
blower motor speed. Set engine speed to 1500-2000 RPM. Cycle
compressor on for 5 seconds and off for 5 seconds, about 20 times to
break-in clutch.
SHAFT SEAL
Shaft seal is not serviceable. If excessive oil is present on
pulley and plate friction surfaces or on compressor shaft nose area,
replace compressor.
ZEXEL ROTARY VANE
CLUTCH ASSEMBLY
NOTE: Discharging A/C system and removing refrigerant lines from
compressor is not necessary to service clutch assembly.
Removal
1) Loosen tensioner and remove drive belt from pulley.
Disconnect clutch electrical connector. Remove compressor mounting
bolts. With refrigerant lines connected lift compressor upward and
forward. Install one front mounting bolt through bottom rear
compressor mounting ear. Tighten bolt so compressor is supported by
mounting bracket.
2) Using Clutch Drive Plate Holder (SA9510AC), remove clutch\
drive plate center bolt. Insert Clutch Drive Plate Remover Sleeve
(SA9506AC) into center of drive plate. Install remover bolt. While
holding clutch remover sleeve, tighten remover bolt and remove drive
plate and shims.
3) Remove pulley external snap ring. Position Puller Center
Adapter (SA9149AC-2) over end of compressor shaft. Attach 3-jaw puller\
to back of pulley. Tighten puller bolt against pulley center adapter
and remove pulley. Remove clutch coil screws. Disconnect clutch coil
wire. Remove clutch coil.
Installation
1) Install coil in original position. Ensure electrical
connector is aligned with indent in front of compressor head. Tighten
screws to 44 INCH lbs. (5 N.m). Place Drive Plate Installer (SA9149AC\
-
3) and thrust bearing on installation bolt and insert through center
of pulley. Finger-tighten pulley installation bolt into compressor
shaft.
2) Finger-tighten nut on installation bolt to align pulley to
compressor. Hold end of bolt and tighten nut until pulley bottoms on
compressor. Loosen nut and remove installation bolt, thrust bearing
and drive plate installer. Install snap ring with tapered side out.
3) Install thrust bearing on installation bolt and insert
through clutch drive plate. Place original shims on installation bolt.
Thread bolt into compressor shaft. Hold end of bolt and tighten nut
until clutch drive plate bottoms out. Loosen nut and remove
installation bolt and thrust bearing. Install center bolt and tighten
to 115 INCH lbs. (13 N.m) using clutch drive plate holder.
4) Using a feeler gauge, measure air gap between drive plate
and pulley. Air gap should be 0.018-0.030" (0.46-0.76 mm). If air gap
is not as specified, add or remove shims as necessary. Install
compressor onto mounting bracket. Tighten front bolts to 36 ft. lbs.
Page 56 of 1691
service to the system in question, if the repair creates
or continues an unsafe condition.
Reasons to Suggest Repair or Replacement
1 - Part is close to the end of its useful life (just above
discard specifications, or weak; failure likely to occur
soon, etc.)
2 - To address a customer need, convenience, or request (to
stiffen ride, enhance performance, eliminate noise,
etc.)
3 - To comply with maintenance recommended by the vehicle's
Original Equipment Manufacturer (OEM)
4 - Technician's recommendation based on substantial and
informed experience
NOTE: Suggested services are always optional. When presenting
suggested repairs to the customer, you must present the
facts, allowing the customer to draw their own conclusions
and make an informed decision about how to proceed.
HEATING, VENTILATION, AND AIR CONDITIONING
SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER VEHICLE
OPERATION
CAUTION: Before working on any air conditioning system, be sure
to review current local, state, federal, and EPA
regulations regarding charging, recycling, and disposal
of refrigerant.
ACCUMULATORS
ACCUMULATOR INSPECTION \
\
\
\
\
\
\
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.
Beyond vehicle
manufacturer's service
interval ............... 3 ............ Suggest replacement.
Dessicant at the end of
its useful life (saturated
with moisture) ......... 1 .. Suggest repair or replacement.
Dessicant bag
deteriorated ........... A ........ ( 1) Require replacement.
Further inspection required.
Leaking ................. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Tubing connection
leaking ................ A .. Require repair or replacement.
Page 153 of 1691
"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.
\
\
\
\
\
\
\
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
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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\
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.
Page 155 of 1691
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.