check oil 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 12 of 1691
A/C C O M PR ESSO R R EFR IG ER AN T O IL C HEC KIN G
1999 D odge P ic ku p R 1500
1999 GENERAL SERVICING
A/C Compressor Refrigerant Oil Checking
All Models
* PLEASE READ THIS FIRST *
NOTE: For compressor applications, see COMPRESSOR APPLICATIONS &
BODY DESIGNATIONS. DO NOT exceed A/C system refrigerant oil
capacity when servicing system. See CAPACITIES.
BODY DESIGNATIONS
BODY DESIGNATIONS (CHRYSLER CORP. CARS) \
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Model ( 1) Body Designation
Avenger & Sebring Coupe ................................ "FJ22" Body
Breeze, Cirrus & Stratus ................................. "JA" Body
Concorde, Intrepid, LHS & 300M ........................... "LH" Body
Neon ..................................................... "PL" Body
Sebring Convertible ...................................... "JX" Body
( 1) - Body codes are determined by fifth character of VIN code.
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BODY DESIGNATIONS (CHRYSLER CORP. LIGHT TRUCKS & VANS) \
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Model Body Designation
Caravan, Town & Country, & Voyager ..................... "NS" Series
Dakota ................................................. "AN" Series
Durango ................................................ "DN" Series
Ram Pickup .......................................... "BR/BE" Series
Ram Van/Wagon .......................................... "AB" Series
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BODY DESIGNATIONS (FORD MOTOR CO. LIGHT TRUCKS & VANS) \
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Model Body Designation
Explorer & Mountaineer .................................. "U" Series
Pickup .................................................. "F" Series
Ranger .................................................. "R" Series
Van ..................................................... "E" Series
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BODY DESIGNATIONS (GENERAL MOTORS CARS) \
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Model ( 1) Body Designation
Alero, Cutlass, Grand Am & Malibu ......................... "N" Body
Aurora & Riviera .......................................... "G" Body
Bonneville, Eighty Eight, LeSabre & LSS ................... "H" Body
Camaro & Firebird ......................................... "F" Body
Catera .................................................... "V" Body
Cavalier & Sunfire ........................................ "J" Body
Century, Grand Prix, Intrigue, Lumina, Monte Carlo &
Regal .................................................... "W" Body
Page 16 of 1691
With Rear Unit ..................... 10.0 ............... 46.0
Ford Motor Co.
"E" Series
With Rear Unit ..................... 13.0 ............... 64.0
Without Rear Unit ................... 9.0 ............... 44.0
Expedition & Navigator ................ (2) ................ ( 2)
Explorer & Mountaineer ................ 7.0 ............... 30.0
F150/F250 Pickup ...................... 9.0 ............... 32.0
F250HD/F350 Pickup .................... 9.0 ............... 32.0
Ranger ................................ 7.0 ............... 30.0
Villager
With Rear Unit ..................... 11.0 ............... 56.0
Without Rear Unit ................... 7.0 ............... 32.0
Windstar
With Rear Unit ..................... 13.0 ............... 56.0
Without Rear Unit ................... 9.0 ............... 44.0
General Motors
"C" & "K" Series
Pickup & Sierra ..................... 8.0 ............... 32.0
Crew Cab & Utility .................. 8.0 ............... 36.0
Suburban, Tahoe & Yukon
With Rear Unit ..................... 11.0 ............... 64.0
Without Rear Unit ................... 8.0 ............... 36.0
"G" Series
With Rear Unit ..................... 11.0 ............... 78.0
Without Rear Unit ................... 8.0 ............... 48.0
"J" Series ............................ 3.4 ............... 21.0
"L" & "M" Series
With Rear Unit ..................... 11.0 ............... 48.0
Without Rear Unit ................... 8.0 ............... 32.0
"P" Series ............................ 8.0 ................ ( 2)
"S" & "T" Series
2.2L ................................ 9.0 .......... 30.0-32.0
4.3L ................................ 8.0 .......... 30.0-32.0
"U" Series
With Rear Unit ..................... 11.0 ............... 46.0
Without Rear Unit ................... 8.0 ............... 32.0
Jeep
Cherokee .............................. 8.1 ............... 20.0
Grand Cherokee ........................ 5.8 ............... 24.0
Wrangler .............................. 8.1 ............... 20.0
( 1) - Total system capacity, unless otherwise noted. Refer to
underhood A/C specification label in engine compartment for
specified oil type.
( 2) - Refrigerant oil and/or refrigerant capacity not available from
manufacturer. Refer to underhood A/C specification label in
engine compartment.
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REFRIGERANT OILS
* PLEASE READ THIS FIRST *
NOTE: Use ONLY the specified oil for the A/C system or compressor.
Always check the underhood A/C specification label or A/C
compressor label before adding refrigerant oil to A/C
compressor/system.
NOTE: For compressor applications, see COMPRESSOR APPLICATIONS &
BODY DESIGNATIONS. DO NOT exceed A/C system refrigerant oil
capacity when servicing system. See CAPACITIES.
Page 17 of 1691
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
Page 18 of 1691
fittings. Coat "O" rings with refrigerant oil, and ensure it is not
twisted during installation. To prevent damage to lines and fittings,
always use 2 wrenches or specified tools. Keep refrigerant oil off
fitting threads. Long term contact of oil on threads may cause future
damage to threads.
PLACING SYSTEM IN OPERATION
After component service or replacement has been completed,
evacuate system thoroughly with a vacuum pump. Charge system with
proper amount of refrigerant. See REFRIGERANT OIL & REFRIGERANT
SPECIFICATIONS article in GENERAL SERVICING. Perform leak test. After
system has been leak tested, check system operation.
NOTE: A/C systems normally will not need additional refrigerant oil
unless oil loss has occurred due to ruptured lines, leaking
compressor seals, compressor overhaul or component
replacement.
CHECKING COMPRESSOR OIL
FORD FS-10 10-CYLINDER
1) Slowly discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove A/C compressor. Drain as much
compressor oil from suction and discharge ports as possible. Rotate
compressor shaft 6-8 revolutions by hand, while pouring oil from
ports. Collect oil in a clean container and measure amount drained. DO
NOT reuse old refrigerant oil.
2) If amount drained is 3-5 ounces, add amount drained plus
one ounce of refrigerant oil to replacement compressor. If amount
drained is more than 5 ounces, add the same amount that was drained
from old compressor. If amount drained is less than 3 ounces, add 3
ounces to compressor. See FORD FS-10 COMPONENT REFRIGERANT OIL
CAPACITIES table. Add refrigerant oil to replacement compressor
through suction port.
3) Use new "O" rings on refrigerant lines. Install A/C
compressor. Evacuate and charge system. Perform leak test. Ensure A/C
system is operating properly.
FORD FS-10 COMPONENT REFRIGERANT OIL CAPACITIES
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Component Ounces
Accumulator/Receiver-Drier
Except Villager .............................................. ( 1)
Villager ..................................................... 2.0
Condenser
Except Contour, Cougar, Mystique, Villager & Windstar ........ 1.0
Contour & Mystique ........................................... 0.7
Villager ................................................. 1.0-1.7
Windstar ..................................................... 1.5
Evaporator
Except Contour, Mystique, Villager & Windstar ................ 3.0
Contour & Mystique ........................................... 0.7
Villager (Front Or Rear) ................................. 1.5-2.5\
Windstar ..................................................... 4.0
Other Components ( 2) ........................................... 2.0
Refrigerant Lines ( 3)
Contour, Cougar & Mystique ................................ 1.0-1.7
( 1) - Drain and measure oil from old accumulator. On Continental,
Page 30 of 1691
4) If bearing is to be removed, remove forcing screw from
puller. With puller still engaged in pulley slots, invert assembly
onto a solid flat surface. Use a hammer and Bearing Remover (J-9398-A)\
to drive bearing from pulley. See Fig. 2 or 3.
NOTE: It is not necessary to remove staking in front of bearing
before removing bearing.
5) Disconnect clutch coil lead. Scribe marks on compressor
and clutch coil for installation reference. Remove clutch coil using
Puller Adapter (J-33023-A) and 2-jaw puller.
Installation
1) Align reference marks made during removal. Using Puller
Adapter (J-33024) and Puller Bar (J-8433-1), press clutch coil onto
compressor. Ensure clutch coil and installer stay lined up during
installation. Using a 1/8" punch, stake clutch coil inner ring in 3
places, 120 degrees apart. Stake size should be 1/2 the area of punch
tip and 0.010-0.015" (0.28-0.38 mm) deep.
NOTE: To ensure proper bearing clearance, it is necessary to remove
old stake metal before installing new bearing.
2) To install pulley bearing, place pulley on Support (J-
21352-A). DO NOT support pulley rim on flat surface, or pulley will be
damaged. Install bearing in pulley using hammer, Bearing Installer (J-
9481-A) and Handle (J-29886).
3) With pulley on support, use Bearing Staking Guide (J-
33019-1) and Bearing Staking Pin (J-33019-2) to stake pulley in 3
places, 120 degrees apart. Reposition pulley on support to ensure full
support under staking pin. Metal stake should be similar to original
stake (down to, but not touching bearing). Position pulley on
compressor.
4) Place Bearing Installer (J-33017) and Puller Guide (J-
33023-A) over inner race of bearing. Using puller, press pulley onto
compressor. Install snap ring. Install shaft key in clutch plate,
allowing key to protrude about 1/8" from rear of clutch plate.
5) Install clutch plate on compressor shaft. Using clutch
plate remover/installer, press clutch plate onto compressor. Ensure
shaft key is still in keyway before installing clutch assembly.
6) Air gap between friction surfaces for HD6/HT6 and HD6/HR-
6HE compressor is 0.020-0.030" (0.51-0.76 mm); for V5 and V7
compressor air gap is 0.015-0.020" (0.38-0.51 mm). On V5 and V7
compressor, using clutch plate spanner, install compressor shaft nut.
Tighten shaft nut to 12.5 ft. lbs. (17 N.m). Check components for
proper rotation.
Page 36 of 1691
Fig. 5.
2) Remove front housing. Remove felt holder and felt washer
from front housing. Remove shaft seal snap ring. Position front
housing (nose up) on cardboard, placed on a flat surface. Using brass
drift, press shaft seal from front housing.
Installation
1) Lubricate new shaft seal with refrigerant oil. DO NOT
touch sealing surfaces. Using a 21-mm socket, press seal into front
housing, and install snap ring. Ensure shaft seal "O" ring side is
facing the front housing (away from compressor). Install felt washer
into felt holder. Using a 14-mm deep socket, install felt washer and
felt holder.
2) Lubricate front housing "O" ring with refrigerant oil.
Install shaft seal protector on compressor shaft. Install new front
housing "O" ring on compressor assembly.
3) Install front housing on compressor assembly. Ensure dowel
pins are aligned. Use care when guiding shaft seal protector through
seal opening. Remove shaft seal protector.
4) Install through-bolts and new brass washers. Using an
INCH-lb. torque wrench, check compressor shaft rotating torque.
Rotating torque should be 45 INCH lbs. (5 N.m) or less. Install clutch\
coil and check clutch hub air gap. See CLUTCH ASSEMBLY.
5) Using refrigerant oil, add same amount of oil to
compressor as was drained from it. Install A/C compressor. Evacuate
and charge system. Perform leak test.
Fig. 5: Compressor Components (Nippondenso 10PA17C Shown; Nippondenso
10PA17 Is Similar)
Courtesy of chrysler corp.
SANDEN SCROLL
Page 37 of 1691
Ford Motor Co. (Taurus 3.4L SHO)
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove A/C compressor. Drain and measure
oil from compressor.
2) Remove pulley assembly. Using Spanner Wrench (T81P-19623-
MH), remove shaft nut and lock washer. Using a steering wheel puller,
remove clutch plate, shaft key and shim. Remove snap ring and pulley
assembly, by hand. If necessary, use a 3-jaw puller to remove pulley
assembly. Remove clutch coil wire from retaining brace on compressor.
Remove snap ring and clutch coil. See Fig. 1.
Installation
1) Install clutch coil. Ensure hole on back of clutch coil is
aligned with pin on compressor head. Install snap ring with beveled
side facing outward. Install clutch coil wire into retaining brace.
2) Slip pulley assembly onto compressor shaft and install
snap ring with beveled side facing outward. Install shim and shaft
key. Align clutch plate with shaft key and install clutch plate. Use
Hub Driven Plate Replacer (T80L-19703-F), if necessary. Using spanner
wrench, install lock washer and shaft nut. Tighten shaft nut to 10-14
ft. lbs. (14-19 N.m).
3) Using a feeler gauge, measure air gap between clutch plate
and pulley assembly at 3 equally spaced locations. Rotate pulley 180
degrees and measure air gap at 3 locations again. Air gap should be 0.
016-0.027" (0.41-0.69 mm). If air gap is not within specification, add\
or remove shims to obtain correct air gap.
4) Add correct amount of refrigerant oil to compressor and
install compressor. See COMPRESSOR REFRIGERANT OIL CHECKING. Evacuate
and charge A/C system. Perform leak test.
SANDEN MSC90-C SCROLL
CLUTCH ASSEMBLY
Removal
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove compressor. Drain oil from
compressor, and measure amount drained.
2) Remove pulley assembly. Using Spanner (MB991367) and Pins\
(MB991386), remove shaft nut. Remove clutch plate, snap ring and rotor\
assembly. Remove snap ring and clutch coil. See Fig. 6.
Installation
1) Install clutch coil. Ensure projection on back of clutch
coil is aligned with pin hole in compressor body. Install snap ring so
that tapered surface is facing outward.
2) Install rotor assembly and snap ring. Align match mark of
clutch plate with match mark of compressor shaft spline and install
clutch plate. Using spanner and pins, install shaft nut.
3) Using a feeler gauge, check air gap between clutch plate
and rotor assembly at more than one place. Air gap should be 0.016-0.
024" (0.40-0.60 mm). If air gap is not within specification, add or
remove shims as necessary. Install pulley assembly.
4) Add same amount of refrigerant oil to compressor as was
drained from it. Install A/C compressor. Evacuate and charge A/C
system. Perform leak test.
Page 40 of 1691
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\
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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 131 of 1691
Refrigerant R-12 based systems use mineral oil, while R-134a
systems use synthetic Polyalkylene Glycol (PAG) oils. Using a mineral
oil based lubricant with R-134a will result in A/C compressor failure
due to lack of proper lubrication.
Following are the most common R-134a refrigerant oils used by
most domestic vehicles:
Chrysler Corp., Eagle & Jeep
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.
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.
NOTE: Use ONLY the specified oil for the appropriate system or A/C
compressor. Always check the underhood A/C specification
label or A/C compressor label before adding refrigerant oil
to A/C system.
SYSTEM SERVICE VALVES
SCHRADER-TYPE VALVES
NOTE: Although similar in construction and operation to a tire
valve, NEVER replace a Schrader-type valve with a tire
valve.
Schrader valve is similar in construction and operation to a
tire valve. See Fig. 4. When a test gauge hose is attached (hose has
built-in valve core depressor), Schrader stem is pushed inward to the
open position and allows system pressure to reach the gauge.
If test hose being used does not have a built-in core
depressor, an adapter must be used. Never attach hoses or adapters to
a Schrader valve unless it is first connected to manifold gauge set.
Fig. 4: Schrader Service Valve (Compressor Location Shown)
SPECIAL VALVE CONNECTORS
On some General Motors models, thread size on high-side