checking 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 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 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 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.
Page 160 of 1691
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 Pressure F ( C) psi (kg/cm)
40 (4.4) ........................................... 53-75 (3.7-5.3\
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60 (15.6) ......................................... 81-104 (5.7-7.3\
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80 (26.7) ....................................... 111-142 (7.8-10.0\
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100 (37.8) ..................................... 156-194 (11.0-13.6\
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120 (48.9) ..................................... 208-259 (14.6-18.2\
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140 (60.0) ..................................... 272-331 (19.1-23.3\
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160 (71.1) ..................................... 353-420 (24.8-29.5\
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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
Page 434 of 1691
Fig. 6: Checking Pinion Depth
Courtesy of Chrysler Corp.
6) Coat lip of oil seal with gear lube. Using appropriate oil
seal installer and handle, install oil seal.
Page 443 of 1691
![DODGE RAM 1999 Service Repair Manual respective differential bearings for reassembly reference.
6) Remove bolt and adjuster lock (if not previously removed)\
.
Loosen, but DO NOT remove, bearing cap bolts. Using Adjuste](/img/12/56915/w960_56915-442.png "DODGE RAM 1999 Service Repair Manual respective differential bearings for reassembly reference.
6) Remove bolt and adjuster lock (if not previously removed)\
.
Loosen, but DO NOT remove, bearing cap bolts. Using Adjuste")
respective differential bearings for reassembly reference.
6) Remove bolt and adjuster lock (if not previously removed)\
.
Loosen, but DO NOT remove, bearing cap bolts. Using Adjuster Rotator
(C-4164), unscrew adjusters from bearing caps. See Figs. 1 and 2.
Remove bolts, bearing caps, adjusters, and differential assembly.
7) Using Holder (C-3281), hold pinion flange. Remove pinion
nut and washer. Scribe reference mark on pinion flange-to-pinion for
reassembly reference. Using appropriate puller, remove pinion flange
from pinion. Remove oil seal for pinion from axle housing. Using soft
drift punch and hammer, drive pinion from axle housing.
NOTE: Front pinion bearing, bearing race, and collapsible spacer
must be replaced after removing pinion from axle housing.
8) Drive pinion bearing races from axle housing. Remove
pinion bearing from pinion. Remove shim(s) located behind pinion
bearing on pinion. Record shim thickness for reassembly reference.
CAUTION: DO NOT remove ring gear from differential carrier unless
components must be replaced or differential carrier flange
runout must be checked.
9) If removing ring gear (and exciter ring on RWAL brake
equipped models), mount differential carrier in soft-jaw vise. Remove
and discard left-hand thread ring gear bolts. Using soft-face hammer,
drive ring gear from differential carrier. Tap exciter ring from
differential carrier, if equipped.
10) If disassembling differential carrier, rotate side gears
and align pinion gears with opening in differential carrier. Remove
pinion gears and pinion gear thrust washers. See Fig. 1. Remove side
gears and side gear thrust washers.
11) If checking differential carrier flange runout, install
differential carrier, bearing races, bearing caps and adjusters in
axle housing. Ensure components are installed in original location.
Thread adjusters into bearing caps.
12) Tighten bearing cap bolts enough to just hold bearing
caps against axle housing. Using Adjuster Rotator (C-4164), tighten
adjuster so no side play exists. Side play can be checked by prying
differential carrier to one side.
13) Install dial indicator on axle housing with stem resting
against differential carrier flange. See Fig. 2. Rotate differential
carrier and note differential carrier flange runout. Replace
differential carrier if runout exceeds .003" (.08 mm).
14) Remove dial indicator, bearing caps, adjusters, bearing
races and differential carrier. Remove differential bearings from
differential carrier (if necessary).
15) Use appropriate puller and adapter (bearing splitter) to\
remove bearing from carrier. On models with Rear Wheel Anti-Lock
(RWAL) brakes, if removing exciter ring, use hammer and soft drift to
tap exciter ring from differential carrier.
Page 458 of 1691
Apply multipurpose lubricant (NLGI grade 2 EP) to "U" joints
and slip joint fittings.
INSPECTION
Abnormal vibration and noise can come from many driveline
sources. Drive shaft vibration/noise increases with vehicle speed
(MPH). A vibration that occurs within a specific speed is not caused
by drive shaft imbalance. Before overhauling driveline, check for
other causes/sources of possible vibration/noise.
TIRES & WHEELS
Check tire inflation and wheel balance. Check for foreign
objects in tread, damaged tread, mismatched tread patterns or
incorrect tire sizes. Check for bent wheels.
CENTER BEARING
Tighten drive shaft center bearing mounting bolts. If bearing
insulator is deteriorated or oil-soaked, or drive shaft can be moved
up/down in support, replace center bearing support assembly.
ENGINE & TRANSMISSION MOUNTS
Tighten mounting bolts. If rubber mounts are deteriorated or
broken, replace as needed.
DRIVE SHAFT(S)
Check drive shaft(s) for missing weights, broken welds, or
for dents affecting balance. Check for undercoating, mud, snow/ice on
drive shaft(s). Clean shafts thoroughly and test drive.
"U" JOINTS
Check for foreign material lodged in joints and flange/yokes.
Check for loose "U" joint-to-flange mounting bolts. Check for worn "U"
joint needle bearings. Check for Reddish-Brown rust-dust around "U"
joint caps. Replace "U" joints if necessary.
ADJUSTMENTS
CHECKING DRIVE SHAFT PHASING
One-Piece Drive Shafts
1) Ensure "U" joint flanges on either end of drive shaft are
in same plane. See Fig. 2. Drive shafts with slip joints between yokes
often have arrows to aid in alignment. If yokes are not in same plane,
disassemble slip joint from drive shaft splines. Install slip joint
back onto drive shaft splines, aligning "U" joint yokes. Test drive.
2) Single tube type drive shaft has slip joint on outside of
"U" joint yoke (at transmission end). If one-piece tube type drive
shaft yokes are out of alignment, the drive shaft is torque-twisted.
Drive shaft must be replaced.
Page 670 of 1691
On cast cylinder heads, if warpage exceeds .003" (.08 mm)
in a 6" span, or .006" (.15 mm) over total length, cylinder head must
be resurfaced. On most aluminum cylinder heads, if warpage exceeds .
002" (.05 mm) in any area, cylinder head must be resurfaced. Warpage
specification may vary with manufacturer.
Cylinder head thickness should be measured to determine
amount of material which can be removed before replacement is
required. Cylinder head thickness must not be less than manufacturer's
specifications.
If cylinder head required resurfacing, it may not align
properly with intake manifold. On "V" type engines, misalignment is
corrected by machining intake manifold surface that contacts cylinder
head. Cylinder head may be machined on surface that contacts intake
manifold.
Using oil stone, remove burrs or scratches from all sealing
surfaces.
VALVE SPRINGS
Inspect valve springs for corroded or pitted valve spring
surfaces which may lead to breakage. Polished spring ends caused by
a rotating spring, indicates that spring surge has occurred. Replace
springs showing evidence of these conditions.
Inspect valve springs for squareness using a 90 degree
straightedge. See Fig. 4. Replace valve spring if out-of-square
exceeds manufacturer's specification.
Fig. 4: Checking Valve Spring Squareness - Typical
This Graphic For General Information Only
Using vernier caliper, measure free length of all valve
springs. Replace springs if not within specification. Using valve
Page 692 of 1691
length of cylinder block at several points.
If warpage exceeds specifications, deck must be resurfaced.
If warpage exceeds manufacturer's maximum tolerance for material
removal, replace block.
DECK HEIGHT
Distance from the crankshaft centerline to the block
deck is termed the deck height. Measure and record front and rear main
journals of crankshaft. To compute this distance, install crankshaft
and retain with center main bearing and cap only. Measure distance
from the crankshaft journal to the block deck, parallel to the
cylinder centerline.
Add one half of the main bearing journal diameter to distance
from crankshaft journal to block deck. This dimension should be
checked at front and rear of cylinder block. Both readings should be
the same.
If difference exceeds specifications, cylinder block must be
repaired or replaced. Deck height and warpage should be corrected at
the same time.
MAIN BEARING BORE & ALIGNMENT
For checking main bearing bore, remove all bearings from
cylinder block and main bearing caps. Install main bearing caps in
original location. Tighten bolts to specification. Using inside
micrometer, measure main bearing bore in 2 areas 90 degrees apart.
Determine bore size and out-of-round. If diameter is not within
specification, block must be align-bored.
For checking alignment, place a straightedge along centerline
of main bearing saddles. Check for clearance between straightedge and
main bearing saddles. Block must be align-bored if clearance is
present.
EXPANSION PLUG REMOVAL & INSTALLATION
Removal
Drill a hole in the center of expansion plug. Remove with
screwdriver or punch. Use care not to damage sealing surface.
Installation
Ensure sealing surface is free of burrs. Coat expansion plug
with sealer. Use a wooden dowel or pipe of slightly smaller diameter,
install expansion plug. Ensure expansion plug is evenly located.
OIL GALLERY PLUG REMOVAL & INSTALLATION
Removal
Remove threaded oil gallery plugs using the appropriate
wrench. Soft, press-in plugs are removed by drilling into plug and
installing a sheet metal screw. Remove plug with slide hammer or
pliers.
Installation
Ensure threads or sealing surface is clean. Coat threaded oil
gallery plugs with sealer and install. Replacement soft press-in plugs
are driven in place with a hammer and drift.
CAMSHAFT
* PLEASE READ THIS FIRST *