DODGE RAM 2001 Service Repair Manual

WINDSHIELD
DESCRIPTION
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCH WELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES
THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURER'S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
OPERATION
The windshield is attached to the window frame
with urethane adhesive. The urethane adhesive is
applied cold and seals the surface area between the
window opening and the glass. The primer adheres
the urethane adhesive to the windshield.
It is difficult to salvage a windshield during the
removal operation. The windshield is part of the
structural support for the roof. The urethane bonding
used to secure the windshield to the fence is difficultto cut or clean from any surface. If the moldings are
set in urethane, it would also be unlikely they could
be salvaged. Before removing the windshield, check
the availability of the windshield and moldings from
the parts supplier.
REMOVAL
(1) Remove inside rear view mirror. (Refer to 23 -
BODY/INTERIOR/REAR VIEW MIRROR - REMOV-
AL).
(2) Remove cowl grill. (Refer to 23 - BODY/EXTE-
RIOR/COWL GRILLE - REMOVAL).
(3) With doors open, remove windshield molding
(Fig. 7). Pull outward on molding beginning at the
bottom of A-pillars using pliers.
(4) Cut urethane bonding from around windshield
using a suitable sharp cold knife (C-4849). A pneu-
matic cutting device can be used but is not recom-
mended (Fig. 8).
(5) Separate windshield from vehicle.
INSTALLATION
WARNING: Allow the urethane at least 24 hours to
cure before returning the vehicle to use.
CAUTION: Roll down the left and right front door
glass and open the rear glass slider (if available)
before installing windshield to avoid pressurizing
the passenger compartment if a door is slammed
before urethane is cured. Water leaks can result.
The windshield fence should be cleaned of most of
its old urethane bonding material. A small amount of
old urethane, approximately 1-2 mm in height,
Fig. 7 Windshield Moldings
1 - WINDSHIELD
2 - WINDSHIELD MOLDING
23 - 148 STATIONARY GLASSBR/BE

should remain on the fence. Do not grind off or com-
pletely remove all old urethane from the fence, the
paint finish and bonding strength will be adversely
affected.
(1) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing against the support spacers. Mark the outside
surface of the glass at the support spacers with a
grease pencil or pieces of masking tape and ink pen
to use as a reference for installation. Remove replace-
ment windshield from windshield opening (Fig. 9).
(2) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 10).
(3) Clean inside of windshield with MOPAR Glass
Cleaner and lint-free cloth.
(4) Apply clear glass primer 25 mm (1 in.) wide
around perimeter of windshield and wipe with a new
clean and dry lint- free cloth.
(5) Apply the molding to the windshield:
(a) Press the upper corners of the molding onto
the windshield.
(b) Press the header section onto the windshield.
(c) Press the A-Pillar sections onto the wind-
shield.
(6) Apply black-out primer onto the glass using the
windshield molding as a guide. The primer should be
15 mm (5/8 in.) wide on the top and sides of the glass
and 25 mm (1 in.) on the bottom of windshield. Allow
at least three minutes drying time.
(7) Locatenewsupport spacers on support brack-
ets and adjust to lowest height.
(8) Position one 5 mm (3/16 in.) soft spacer (p/n
55028214) at the bottom of the windshield fence (Fig.
11).(9) Apply a 13mm (1/2 in.) high and 10mm (3/8 in.)
wide bead of urethane around the perimeter of wind-
shield. At the bottom, apply the bead 7 mm (1/4 in.)
inboard from the glass edge. On the three sides
where the molding is on the glass, follow the edge of
molding. The urethane bead should be shaped in a
triangular cross-section, this can be achieved by
notching the tip of the applicator (Fig. 12).
(10) With the aid of a helper, position the wind-
shield over the windshield opening. Align the refer-
ence marks at the bottom of the windshield to the
support spacers.
Fig. 8 Cut Urethane Around Windshield
1 - WINDSHIELD
2 - COLD KNIFE
Fig. 9 Center Windshield and Mark at Support
1 - WINDSHIELD
2 - INDEX MARKS
3 - SUPPORT SPACERS
Fig. 10 Work Surface Set up
1 - WINDSHIELD AND MOULDINGS
2 - URETHANE BEAD AROUND GLASS 7mm (.3 in.) FROM
EDGE
3 - BLOCKS
BR/BESTATIONARY GLASS 23 - 149
WINDSHIELD (Continued)

(11) Slowly lower windshield glass to the fence
opening guiding the lower corners into proper posi-
tion. Beginning at the bottom and continuing to the
top, push glass onto fence along the A-Pillars. Push
windshield inward to the fence at the bottom corners
(Fig. 13).
(12) Push windshield upward, snug with roof and
ratchet up the adjustable support brackets. Discard
tab from support spacer.
(13) Using clean water, lightly mist the support
spacers.
(14) Clean excess urethane from exterior with
MOPARž Super Clean or equivalent.
(15) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
masking tape spaced 250 mm (10 in.) apart to hold
molding in place until urethane cures.
(16) Install cowl grill. (Refer to 23 - BODY/EXTE-
RIOR/COWL GRILLE - INSTALLATION).
(17) Install rear view mirror support bracket.
(Refer to 23 - BODY/INTERIOR/REAR VIEW MIR-
ROR - INSTALLATION).
(18) Install rear view mirror. (Refer to 23 - BODY/
INTERIOR/REAR VIEW MIRROR - INSTALLA-
TION).
(19) After urethane has cured, remove tape strips
and water test windshield to verify repair.
Fig. 11 Position Urethane Compression Spacer
1 - URETHANE COMPRESSION SPACER
2 - FENCE
Fig. 12 Applicator Tip
1 - APPLICATOR TIP
Fig. 13 Lower Windshield Into Position
1 - COMPRESSION SPACER
2 - WINDSHIELD
3 - ADJUSTABLE SUPPORT SPACERS
23 - 150 STATIONARY GLASSBR/BE
WINDSHIELD (Continued)

QUARTER WINDOW
REMOVAL
(1) Remove quarter trim panel.
(2) Remove the latch retaining screws from the cab
rear side panel (Fig. 14).
(3) Remove the frame/hinge retaining nuts from
the B-pillar.
(4) Remove the window glass from the cab.
(5) If necessary, remove the latch from the glass.
INSTALLATION
(1) If removed, install the latch to the glass.
Tighten the screw to 6 N´m (60 in. lbs.) torque.
(2) Center the window glass at the opening, insert
the hinge studs in the B-pillar holes, and install the
retaining nuts. Tighten the nuts to 11 N´m (95 in.
lbs.) torque.
(3) Attach the latch to the rear side panel with the
screws. Tighten the screws with the latch in the lock
position and pushing rearward on the latch. Tighten
the screws to 11 N´m (95 in. lbs.) torque.(4) Test the vent window for water leaks.
(5) Install quarter trim panel.
Fig. 14 Vent WindowÐClub Cab
1 - QUARTER GLASS
2-LATCH
BR/BESTATIONARY GLASS 23 - 151

WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
B-PILLAR DOOR SEAL
REMOVAL.............................152
INSTALLATION..........................152
COWL WEATHERSTRIP
REMOVAL.............................153
INSTALLATION..........................153
DOOR OPENING SEAL
REMOVAL.............................153
INSTALLATION..........................153
FRONT DOOR GLASS RUN WEATHERSTRIP
REMOVAL.............................153
INSTALLATION..........................154FRONT DOOR INNER BELT WEATHERSTRIP
REMOVAL.............................154
INSTALLATION..........................154
FRONT DOOR OUTER BELT WEATHERSTRIP
REMOVAL.............................154
INSTALLATION..........................154
FRONT DOOR UPPER CORNER SEAL
REMOVAL.............................154
INSTALLATION..........................155
FRONT DOOR SECOND WEATHERSTRIP
REMOVAL.............................155
INSTALLATION..........................155
B-PILLAR DOOR SEAL
REMOVAL
(1) Warm the seal and body metal to approxi-
mately 38ÉC (100ÉF) using a suitable heat lamp or
heat gun.
(2) Pull seal from painted surface (Fig. 1).
INSTALLATION
(1) Remove adhesive tape residue from painted
surface of vehicle.
(2) If seal is to be reused, remove tape residue
from seal. Clean back of seal with MOPARž, Super
Kleen solvent or equivalent. Wipe seal dry with lint
free cloth. Apply new body side molding (two sided
adhesive) tape to back of seal.
(3) Clean body surface with MOPARž, Super
Kleen solvent or equivalent. Wipe surface dry with
lint free cloth.
(4) Remove protective cover from tape on back of
seal and apply seal to body.
(5) Heat body and seal, see step one. Firmly press
seal to body surface to assure adhesion (Fig. 1).
Fig. 1 B-Pillar Secondary Seal
1 - BÐPILLAR SECONDARY SEAL
2 - DOOR
23 - 152 WEATHERSTRIP/SEALSBR/BE

COWL WEATHERSTRIP
REMOVAL
(1) Grasp cowl seal and pull from cowl flange.
(2) Separate cowl seal from vehicle (Fig. 2).
INSTALLATION
(1) Position cowl seal on flange and press into
place.
DOOR OPENING SEAL
REMOVAL
(1) Remove A-pillar molding. (Refer to 23 - BODY/
INTERIOR/A-PILLAR TRIM - REMOVAL)
(2) Remove cowl pane.(Refer to 23 - BODY/INTE-
RIOR/COWL TRIM COVER - REMOVAL)
(3) Remove sill cover. (Refer to 23 - BODY/INTE-
RIOR/DOOR SILL TRIM - REMOVAL)
(4) Remove B-pillar trim. (Refer to 23 - BODY/IN-
TERIOR/B-PILLAR TRIM - REMOVAL)
(5) Pull seal from pinch flange around door open-
ing (Fig. 3).
INSTALLATION
(1) Press seal onto pinch flange around door open-
ing (Fig. 3).
(2) Install B-pillar trim panel. (Refer to 23 -
BODY/INTERIOR/B-PILLAR TRIM - INSTALLA-
TION)
(3) Install cowl panel. (Refer to 23 - BODY/INTE-
RIOR/COWL TRIM COVER - INSTALLATION)
(4) Install sill cover. (Refer to 23 - BODY/INTERI-
OR/DOOR SILL TRIM - INSTALLATION)(5) Install A-pillar molding. (Refer to 23 - BODY/
INTERIOR/A-PILLAR TRIM - INSTALLATION)
FRONT DOOR GLASS RUN
WEATHERSTRIP
REMOVAL
(1) Remove inner door belt weatherstrip. (Refer to
23 - BODY/WEATHERSTRIP/SEALS/FRONT DOOR
INNER BELT WEATHERSTRIP - REMOVAL)
(2) Pull door glass run weatherstrip from channel
around window opening (Fig. 4).
Fig. 2 Cowl Seal
1 - COWL
2 - COWL SEAL
Fig. 3 Door Opening SealÐClub Cab
1 - DOOR SEAL
2 - BODY
Fig. 4 Door Glass Run Weatherstrip
1 - GLASS RUN WEATHERSTRIP
BR/BEWEATHERSTRIP/SEALS 23 - 153

INSTALLATION
(1) Press door glass run weatherstrip into channel
around window opening (Fig. 4).
(2) Install inner door belt weatherstrip. (Refer to
23 - BODY/WEATHERSTRIP/SEALS/FRONT DOOR
INNER BELT WEATHERSTRIP - INSTALLATION)
FRONT DOOR INNER BELT
WEATHERSTRIP
REMOVAL
(1) Remove door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
(2) Lift inner door belt weatherstrip upward (Fig.
5).
(3) Separate inner door belt weatherstrip from
door.
INSTALLATION
(1) Position inner door belt weatherstrip on door.
(2) Press inner door belt weatherstrip downward
to seat.
(3) Install door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION)
FRONT DOOR OUTER BELT
WEATHERSTRIP
REMOVAL
(1) Roll door glass down.
(2) Remove mirror. (Refer to 23 - BODY/EXTERI-
OR/SIDE VIEW MIRROR - REMOVAL)
(3) Using a hook tool inserted into the end of the
belt weatherstrip, lift upward.(4) Separate outer door belt weatherstrip from
door (Fig. 6).
INSTALLATION
(1) Position outer door belt weatherstrip on door.
(2) Press weatherstrip downward to seat.
(3) Install mirror. (Refer to 23 - BODY/EXTERI-
OR/SIDE VIEW MIRROR - INSTALLATION)
FRONT DOOR UPPER CORNER
SEAL
REMOVAL
(1) Remove the push-in fasteners attaching the
upper corner seal to the front door (Fig. 7).
(2) Separate the upper corner seal from the door.
INSTALLATION
(1) Position the upper corner seal on the door.
(2) Install the push-in fasteners attaching the
upper corner seal to the front door (Fig. 7).
FRONT DOOR SECOND
WEATHERSTRIP
REMOVAL
(1) Remove the push-in fasteners attaching the
secondary seal to the inner door panel.
(2) Separate the secondary seal from the inner
door panel (Fig. 8).
Fig. 5 Inner Door Belt Weatherstrip
1 - DOOR
2 - INNER BELTLINE WEATHERSEAL
Fig. 6 Outer Door Belt Weatherstrip
1 - OUTER BELTLINE WATHERSTRIP
2 - DOOR
23 - 154 WEATHERSTRIP/SEALSBR/BE
FRONT DOOR GLASS RUN WEATHERSTRIP (Continued)

INSTALLATION
(1) Position the secondary seal on the inner door
panel.(2) Install the push-in fasteners attaching the sec-
ondary seal to the inner door panel.
Fig. 7 Upper Corner SealÐQuad Cab
1 - UPPER CORNER SEAL
2 - PUSHÐIN FASTENER
Fig. 8 Front Door Secondary SealÐQuad Cab
1 - FRONT DOOR
2 - SECONDARY SEAL
BR/BEWEATHERSTRIP/SEALS 23 - 155
FRONT DOOR 2ND WEATHERSTRIP (Continued)

HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION............................1
OPERATION.............................1
DIAGNOSIS AND TESTING..................2
A/C PERFORMANCE.....................2
HEATER PERFORMANCE.................6STANDARD PROCEDURE...................7
DIODE REPLACEMENT...................7
SPECIFICATIONS.........................8
CONTROLS..............................9
DISTRIBUTION..........................31
PLUMBING.............................40
HEATING & AIR
CONDITIONING
DESCRIPTION - HEATER AND AIR
CONDITIONER
All vehicles are equipped with a common HVAC
housing assembly (Fig. 1). The system combines air
conditioning, heating, and ventilating capabilities in
a single unit housing mounted under the instrument
panel. On heater-only systems, the evaporator coil
and recirculation door are omitted from the housing.
DESCRIPTION - COOLING SYSTEM
REQUIREMENTS
To maintain the performance level of the HVAC
system, the engine cooling system must be properly
maintained. The use of a bug screen is not recom-
mended. Any obstructions in front of the radiator or
condenser will reduce the performance of the air con-
ditioning and engine cooling systems.The engine cooling system includes the heater core
and the heater hoses. Refer to Cooling for more infor-
mation before the opening of, or attempting any ser-
vice to the engine cooling system.
DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT
The two refrigerant system service ports are used
to charge, recover/recycle, evacuate, and test the air
conditioning refrigerant system. Unique service port
coupler sizes are used on the R-134a system, to
ensure that the refrigerant system is not accidentally
contaminated by the use of the wrong refrigerant
(R-12), or refrigerant system service equipment.
OPERATION - HEATER AND AIR CONDITIONER
The heater and optional air conditioner are blend-air
type systems. In a blend-air system, a blend door con-
trols the amount of unconditioned air (or cooled air from
the evaporator on models with air conditioning) that is
allowed to flow through, or around, the heater core. A
temperature control knob on the A/C Heater control
panel determines the discharge air temperature by con-
trolling an electric actuator, which moves the blend
door. This allows an almost immediate control of the
output air temperature of the system.
The mode control knob on the heater-only or A/C
Heater control panel is used to direct the conditioned
air to the selected system outlets. Both mode control
switches use engine vacuum to control the mode
doors, which are operated by vacuum actuators.
On air conditioned vehicles, the outside air intake
can be shut off by selecting the Recirculation Mode
with the mode control knob. This will operate a vac-
uum actuated recirculation door that closes off the
outside fresh air intake and recirculates the air that
is already inside the vehicle.
The optional air conditioner for all models is designed
for the use of non-CFC, R-134a refrigerant. The air con-
ditioning system has an evaporator to cool and dehu-
midify the incoming air prior to blending it with the
Fig. 1 COMMON BLEND-AIR HEATER-AIR
1 - HEATER CORE
2 - BLEND DOOR
3 - EVAPORATOR (A/C ONLY)
4 - RECIRCULATION DOOR (A/C ONLY)
5 - FLOOR/PANEL DOOR
6 - FLOOR/DEFROST DOOR
BR/BEHEATING & AIR CONDITIONING 24 - 1