hood open DODGE RAM 2003 Service Owner's Manual

STEERING COLUMN OPENING
COVER
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Remove the two lower screws. (Fig. 21)
(2) Using a trim stick C-4755 or equivalent,
release the upper clips and remove the cover.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the cover and seat the upper clips
fully.
(2) Install the two lower screws.
STEERING COLUMN OPENING
SUPPORT BRACKET
REMOVAL
(1) Remove the steering column opening cover.
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - REMOVAL)
(2) Remove the two screws and remove the diag-
nostic connector.
(3) Loosen the screws and remove the hood release
handle from the bracket.
(4) Remove the two bracket screws and slide
upward off the locating tabs to remove. (Fig. 22)
Fig. 21 STEERING COLUMN OPENING COVER
1 - SCREWS (2)
2 - COVER
Fig. 22 COLUMN OPENING BRACKET
1 - LOCATING TABS
2 - INSTRUMENT PANEL
3 - REINFORCEMENT BRACKET
4 - SCREWS (2)
DRINSTRUMENT PANEL 23 - 61

INSTALLATION
(1) Position the bracket onto the locating tabs and
slide down.
(2) Install the two screws.
(3) Install the diagnostic connector and install the
two screws.
(4) Install the hood release handle and tighten the
screws.
(5) Install the steering column opening cover.
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - INSTALLA-
TION)
STORAGE BIN
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Remove the center bezel. (Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL
CENTER BEZEL - REMOVAL)
(2) Remove the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - REMOVAL)
(3) Remove the four screws and remove the bin.
(Fig. 23)
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Install the storage bin and install the four
screws.
(2) Install the floor console. (Refer to 23 - BODY/
INTERIOR/FLOOR CONSOLE - INSTALLATION)
(3) Install the center bezel. (Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL
CENTER BEZEL - INSTALLATION)
Fig. 23 STORAGE BIN
1 - SCREWS (4)
2 - STORAGE BIN
23 - 62 INSTRUMENT PANELDR
STEERING COLUMN OPENING SUPPORT BRACKET (Continued)

erant system. Refer to the operating instructions sup-
plied by the equipment manufacturer for the proper
care and use of this equipment.
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
If the refrigerant system has been open to the
atmosphere, it must be evacuated before the system
can be charged. If moisture and air enters the system
and becomes mixed with the refrigerant, the com-
pressor head pressure will rise above acceptable
operating levels. This will reduce the performance of
the air conditioner and damage the compressor.
Evacuating the refrigerant system will remove the
air and boil the moisture out of the system at near
room temperature. To evacuate the refrigerant sys-
tem, use the following procedure:
(1) Connect a R-134a refrigerant recovery/recy-
cling/charging station that meets SAE Standard
J2210 and a manifold gauge set to the refrigerant
system of the vehicle.
(2) Recover the refrigerant(Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE).
(3) Open the low and high side valves and start
the charging station vacuum pump. When the suc-
tion gauge reads 88 kPa (26 in. Hg.) vacuum or
greater, close all of the valves and turn off the vac-
uum pump.
(a) If the refrigerant system fails to reach the
specified vacuum, the system has a leak that must
be corrected. (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - DIAGNOSIS AND
TESTING - REFRIGERANT SYSTEM LEAKS)
(b) If the refrigerant system maintains the spec-
ified vacuum for five minutes, restart the vacuum
pump, open the suction and discharge valves and
evacuate the system for an additional ten minutes.
(4) Close all of the valves, and turn off the charg-
ing station vacuum pump.
(5) The refrigerant system is now ready to be
charged with R-134a refrigerant. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
STANDARD PROCEDURE - REFRIGERANT
SYSTEM CHARGE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
After the refrigerant system has been tested for
leaks and evacuated, a refrigerant charge can be
injected into the system. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - SPECIFICA-
TIONS - CHARGE CAPACITY)
A R-134a refrigerant recovery/recycling/charging
station that meets SAE Standard J2210 must be
used to charge the refrigerant system with R-134a
refrigerant. Refer to the operating instructions sup-
plied by the equipment manufacturer for proper care
and use of this equipment.
The R-134a refrigerant charge capacity for this
vehicle is 0.7371 Kg (26 oz.).
NOTE: Always refer to the HVAC underhood sticker
for current refrigerant charge level and refrigerant
oil specifications.
SPECIFICATIONS - CHARGE CAPACITY
The R-134a refrigerant system charge capacity for
this vehicle is: 0.7371 Kg. (26 oz.).
A/C COMPRESSOR
DESCRIPTION
DESCRIPTION
The air conditioning system uses a Sanden SD-7
reciprocating swash plate-type compressor on all
models. This compressor has a fixed displacement of
165 cubic centimeter and has both the suction and
discharge ports located on the cylinder head. A label
identifying the use of R-134a refrigerant is located on
the compressor.
DESCRIPTION - HIGH PRESSURE RELIEF
VALVE
A high pressure relief valve is located on the com-
pressor cylinder head, which is on the rear of the
compressor. This mechanical valve is designed to
vent refrigerant from the system to protect against
damage to the compressor and other system compo-
DRPLUMBING 24 - 35
PLUMBING (Continued)

NOTE: Removal of the front bumper on the V-10 is
required, failure to do so could result in damage to
the condenser assembly and the bumper.
(3) Remove the front bumper assembly from the
vehicle(Refer to 13 - FRAME & BUMPERS/
BUMPERS/FRONT BUMPER - REMOVAL).
(4) Remove hood latch bolts and set hood latch
assembly aside(Refer to 23 - BODY/HOOD/LATCH -
REMOVAL).
(5) Remove a/c lines from condenser(Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - REMOVAL) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
SUCTION LINE - REMOVAL). Install plugs or tape
over all open connections (Fig. 7).
(6) Remove two bolts from top of condenser shroud
assembly (Fig. 8).
(7) Lift condenser and shift assembly to passenger
side of vehicle and remove from vehicle.
(8) With condenser and shroud on a clean flat
work area remove condenser retainer screws and sep-
arate condenser from shroud.
INSTALLATION
INSTALLATION - 3.7, 4.7 and 5.7L ENGINES
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
(1) Install the condenser lower dowel pins to the
bottom of the support rail.
(2) Position the condenser until both of the con-
denser studs are installed through the holes in the
upper support rail. Tighten the mounting nuts to 5.3
N´m (47 in. lbs.).
(3) Remove the tape or plugs from the refrigerant
line fittings on the condenser outlet and the liquid
line. Install the liquid line or the liquid line jumper
to the condenser outlet. (Refer to 24 - HEATING &
Fig. 7 CONDENSER LINES
1 - Discharge line to condenser
2 - Mounting nut
3 - Mounting nut
4 - Liquid line
5 - A/C condenser shroud
6 - A/C condenser
Fig. 8 A/C CONDENSER
1 -A/C shroud mounting bolt
2 - Hood latch bolt
3 - Hood latch assembly
4 - Hood latch bolt
5 - A/C shroud mounting bolt
6 - A/C discharge line
7 - A/C liquid line
8 - Condenser to shroud mounting bolts (5)
9 - A/C condenser
10 - Condenser to shroud mounting bolts (5)
DRPLUMBING 24 - 41
A/C CONDENSER (Continued)

air and boil the moisture out of the system at near
room temperature. To evacuate the refrigerant sys-
tem, use the following procedure:
(1) Connect a R-134a refrigerant recovery/recy-
cling/charging station that meets SAE Standard
J2210 and a manifold gauge set (if required) to the
refrigerant system of the vehicle and recover refrig-
erant.
(2) Open the low and high side valves and start
the charging station vacuum pump. When the suc-
tion gauge reads 88 kPa (26 in. Hg.) vacuum or
greater, close all of the valves and turn off the vac-
uum pump.
(a) If the refrigerant system fails to reach the
specified vacuum, the system has a leak that must
be corrected. See Refrigerant System Leaks in the
Diagnosis and Testing section of this group for the
procedures.
(b) If the refrigerant system maintains the spec-
ified vacuum for five minutes, restart the vacuum
pump, open the suction and discharge valves and
evacuate the system for an additional ten minutes.
(3) Close all of the valves, and turn off the charg-
ing station vacuum pump.
(4) The refrigerant system is now ready to be
charged with R-134a refrigerant(Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/REFRIG-
ERANT - STANDARD PROCEDURE).
STANDARD PROCEDURE- REFRIGERANT
RECOVERY
WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) AND (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION) BEFORE PERFORMING THE FOLLOWING
OPERATION.
A R-134a refrigerant recovery/recycling/charging
station that meets SAE Standard J2210 must be
used to recover the refrigerant from an R-134a refrig-
erant system. Refer to the operating instructions sup-
plied by the equipment manufacturer for the proper
care and use of this equipment.
STANDARD PROCEDURE- REFRIGERANT
SYSTEM CHARGE
WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) AND (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION) BEFORE PERFORMING THE FOLLOWING
OPERATION.
After the refrigerant system has been tested for
leaks and evacuated, a refrigerant charge can beinjected into the system. See Refrigerant Charge
Capacity in the Service Procedures section of this
group for the proper amount of the refrigerant
charge, this fill level can also be found on a label
attached under the hood of the vehicle..
A R-134a refrigerant recovery/recycling/charging
station that meets SAE Standard J2210 must be
used to charge the refrigerant system with R-134a
refrigerant. Refer to the operating instructions sup-
plied by the equipment manufacturer for the proper
care and use of this equipment.
The R-134a refrigerant system charge capacity for
this vehicle is:
²If equipped with a 3.7L or a 4.7L engine charge
to 0.6804 Kg. (24 oz.).
²If equipped with a 5.9L engine charge to 0.7371
Kg. ( 26 oz.).
REFRIGERANT LINE COUPLER
DESCRIPTION
Spring-lock type refrigerant line couplers are used
to connect many of the refrigerant lines and other
components to the refrigerant system. These couplers
require a special tool for disengaging the two coupler
halves.
OPERATION
The spring-lock coupler is held together by a garter
spring inside a circular cage on the male half of the
fitting (Fig. 16). When the two coupler halves are
connected, the flared end of the female fitting slips
behind the garter spring inside the cage on the male
fitting. The garter spring and cage prevent the flared
end of the female fitting from pulling out of the cage.
Three O-rings on the male half of the fitting are
used to seal the connection. These O-rings are com-
patible with R-134a refrigerant and must be replaced
with O-rings made of the same material.
Secondary clips are installed over the two con-
nected coupler halves at the factory for added blowoff
protection.
REMOVAL
WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION) BEFORE PERFORMING THE FOLLOWING
OPERATION.
(1) Recover the refrigerant from the refrigerant
system(Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT - STANDARD
PROCEDURE).
24 - 52 PLUMBINGDR
REFRIGERANT (Continued)