torque DODGE RAM 2003 Service Repair Manual

center caps for more information refer to Owner's
Manual.
The tires on both wheels must be completely raised
off the ground when tightening the lug nuts. This
will ensure correct wheel centering and maximum
wheel clamping.
A two piece flat face lug nut with right-hand
threads is used for retaining the wheels on the hubs
(Fig. 24).
The dual rear wheel lug nuts should be tightened
according to the following procedure:
²Place two drops of oil to the interface of the nut/
washer (Fig. 24) before installing on the wheel stud.
NOTE: Do not use more then two drops of oil on
the nut/washer, since the center caps attach in this
area.
²Tighten the wheel lug nuts in the numbered
sequential pattern until they are snug tight. Then
tighten lug nut to specified torque following same
number sequence, (Refer to 22 - TIRES/WHEELS/
WHEELS - SPECIFICATIONS).
²Tighten lug nuts in same numbered sequence a
second time to the specified torque. This will ensure
that the wheels are thoroughly mated.²Check lug nut specified torque after 100 miles
(160 kilometers). Also after 500 miles (800 kilome-
ters) of vehicle operation.
NOTE: Wheel lug nuts should be tightened to spec-
ified torque at every maintenance interval thereafter.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
1500 Series
Lug Nut 9/16 X 18 with
60É Cone180 135 Ð
2500 Series
Lug Nut 9/16 X 18 with
60É Cone180 135 Ð
3500 Series
Lug Nut 9/16 X 18 with
Flat Washer195 145 Ð
Fig. 24 Oil Location
1 - PLACE TWO DROPS OF OIL HERE
DRTIRES/WHEELS 22 - 13
WHEELS (Continued)

BODY
TABLE OF CONTENTS
page page
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS . 1
DIAGNOSIS AND TESTING - WIND NOISE . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY
LUBRICATION.........................3
STANDARD PROCEDURE - HEAT STAKING . . 3
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR........................3
STANDARD PROCEDURE - BUZZ, SQUEAK
& RATTLE...........................11
SPECIFICATIONS - TORQUE..............12SPECIAL TOOLS
BODY..............................14
TAILGATE..............................15
DOOR - FRONT.........................18
DOORS - REAR.........................28
EXTERIOR.............................36
HOOD.................................46
INSTRUMENT PANEL.....................50
INTERIOR..............................63
PAINT.................................74
SEATS................................76
STATIONARY GLASS.....................86
WEATHERSTRIP/SEALS...................91
BODY STRUCTURE......................95
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE AN OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
²AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL ± BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
²DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
²Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
²Always have a fire extinguisher ready for use
when welding.
²Disconnect the negative (-) cable clamp from
the battery when servicing electrical components
that are live when the ignition is OFF. Damage to
electrical system can result.²Do not use abrasive chemicals or compounds
on painted surfaces. Damage to finish can result.
²Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
²Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
DRBODY 23 - 1

SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
Description N´m Ft. Lbs. In. Lbs.
A-pillar trim/grab handle bolts 6 Ð 55
Body Isolator/cab bolts 81 60 Ð
Cargo box bolts 108 80 Ð
Cargo box tie down/cleat bolts 34 25 Ð
Center seat assembly nuts*25 18 Ð
Center seat cushion/hinge bolts*20 15 Ð
Center seat back hinge to storage bin bolts*25 18 Ð
Center seat back free pivot hinge bolt*25 18 Ð
Center seat back inertia hinge pivot bolt*10 Ð 89
Center seat inertia hinge to seat back bolts*25 18 Ð
Fender bolts - front lower 9 Ð 80
Fender bolts - lower inside 17 13 Ð
Fender to hinge support bolts 11 8 Ð
Fender to upper fender rail bolts 9 Ð 80
Footmans loop bolts 12 9 Ð
Front center seat nuts*25 18 Ð
Front door glass lift plate nuts 10 Ð 89
Front door hinge to a-pillar nuts 28 21 Ð
Front door hinge to door nuts/bolts 28 21 Ð
Front door inside handle bolt 9 Ð 80
Front door latch adjustment screw 3 Ð 30
Front door latch assembly bolts 10 Ð 89
Front door latch striker bolts 28 21 Ð
Front door latch striker bolts 28 21 Ð
Front door regulator bolts 10 Ð 89
Front door regulator stabilizer nuts 10 Ð 89
Front door remote handle actuator nuts 10 Ð 89
Front door run channel screws 10 Ð 89
Front seat assembly front bolts*28 30 Ð
Front seat assembly rear bolts*40 30 Ð
Front seat track nuts*25 18 Ð
Fuel fill door bolts 9 Ð 80
Hood hinge to fender rail bolts 20 15 Ð
Hood latch bolts 11 8 Ð
Hood latch striker/safety catch bolts 11 8 Ð
Hood hinge to hood nuts 23 17 Ð
Instrument panel center bracket bolts 12 9 Ð
Instrument panel column support bolts 14 10 Ð
Instrument panel side mounting bolts 12 9 Ð
23 - 12 BODYDR
BODY (Continued)

ADJUSTMENTS
ADJUSTMENT
NOTE: For vehicles with four doors, it is recom-
mended that you adjust the rear door before adjust-
ing the front door. (Refer to 23 - BODY/DOORS -
REAR/DOOR - ADJUSTMENTS)
²Door adjustment measurements should be
taken from stationary or welded body panels like
the roof, rocker or quarter panels.
²During adjustment procedures, it is recom-
mended that all the hinge fasteners be loosened
except for the upper most fasteners. Adjustments
can be made using the upper bolts to hold the door
with final torque of the fasteners occurring after
correct door positioning is achieved.
²A suitable body sealant should be used when
removing or moving the hinges.
FORE/AFT
NOTE: Fore/aft (lateral) door adjustment is done by
loosening the hinge to the hinge pillar fasteners
one hinge at a time and moving the door to the cor-
rect position.
(1) Support the door with a suitable lifting device.
(2) Loosen the hinge to hinge pillar fasteners.
(Refer to 23 - BODY/DOOR - FRONT/HINGE -
REMOVAL)(3) Adjust the door to the correct position. (Refer
to 23 - BODY/BODY STRUCTURE/GAP AND
FLUSH - SPECIFICATIONS)
(4) Tighten the hinge pillar fasteners to 28 N´m
(21 ft. lbs.).
UP/DOWN
NOTE: Up/down door adjustment is done by loosen-
ing either the hinge to the hinge pillar fasteners or
the hinge to door fasteners and moving the door to
the correct position.
NOTE: When adjustment of the door requires the
loosening of the door to hinge fasteners, it will be
necessary to separate the epoxy bonded washers
with a chisel or other suitable tool.
NOTE: When the up/down adjustments are done
correctly, the top of the door is positioned over
flush to the roof. (Refer to 23 - BODY/BODY STRUC-
TURE/GAP AND FLUSH - SPECIFICATIONS)
(1) Support the door with a suitable lifting device.
(2) Loosen the latch striker bolts. (Refer to 23 -
BODY/DOOR - FRONT/LATCH STRIKER -
REMOVAL)
(3) Loosen the hinge to door fasteners (Refer to 23
- BODY/DOOR - FRONT/DOOR - REMOVAL) or
loosen the hinge to hinge pillar fasteners (Refer to 23
- BODY/DOOR - FRONT/HINGE - REMOVAL).
(4) Adjust the door to the correct position. (Refer
to 23 - BODY/BODY STRUCTURE/GAP AND
FLUSH - SPECIFICATIONS)
(5) Tighten the hinge pillar fasteners or the door
to hinges fasteners to 28 N´m (21 ft. lbs.).
(6) Tighten the latch striker bolts. (Refer to 23 -
BODY/DOOR - FRONT/LATCH STRIKER - INSTAL-
LATION)
IN/OUT
NOTE: In/out door adjustment is done by loosening
the hinge to door fasteners one hinge at a time and
moving the door to the correct position.
NOTE: When adjustment of the door requires the
loosening of the door to hinge fasteners, it will be
necessary to separate the epoxy bonded washers
with a chisel or other suitable tool.
(1) Support the door with a suitable lifting device.
(2) Loosen the latch striker bolts. (Refer to 23 -
BODY/DOOR - FRONT/LATCH STRIKER -
REMOVAL)
Fig. 1 FRONT DOOR
1 - NUTS (2)
2 - UPPER HINGE
3 - STUDS
4 - FRONT DOOR
5 - WIRE HARNESS
6 - LOWER HINGE
7 - ELECTRICAL CONNECTORS (2)
8 - BOLTS (2)
DRDOOR - FRONT 23 - 19
DOOR (Continued)

DOORS - REAR
TABLE OF CONTENTS
page page
DOOR
REMOVAL.............................28
INSTALLATION.........................28
ADJUSTMENTS
ADJUSTMENT........................28
DOOR GLASS
REMOVAL.............................30
INSTALLATION.........................30
EXTERIOR HANDLE
REMOVAL.............................30
INSTALLATION.........................30
GLASS RUN CHANNEL
REMOVAL.............................30
INSTALLATION.........................31
HINGE
REMOVAL.............................31
INSTALLATION.........................31
INSIDE HANDLE ACTUATOR
REMOVAL.............................31
INSTALLATION.........................32
LATCH
REMOVAL.............................32INSTALLATION.........................32
ADJUSTMENTS
ADJUSTMENT........................32
LATCH STRIKER
REMOVAL.............................33
INSTALLATION.........................33
ADJUSTMENTS
ADJUSTMENT........................33
TRIM PANEL
REMOVAL.............................33
INSTALLATION.........................33
WATERDAM
REMOVAL.............................34
INSTALLATION.........................34
WINDOW REGULATOR - POWER
REMOVAL.............................34
INSTALLATION.........................34
WINDOW REGULATOR - MANUAL
REMOVAL.............................35
INSTALLATION.........................35
DOOR
REMOVAL
(1) Disconnect the door wire harness electrical con-
nector at the b-pillar. (Fig. 1)
(2) Using a grease pencil or equivalent, mark the
outline of the door hinges on the door to aid in instal-
lation.
(3) Support the door with a suitable lifting device.
NOTE: The epoxy bonded washers should not be
seperated from the hinge. If the washers are
removed the door may have to be re-adjusted.
(4) Remove the nuts and bolts attaching the door
hinges to the door.
INSTALLATION
(1) Support the door with a suitable lifting device
and install the door onto the hinges.
(2) Install the bolts, nuts and washers, if there
were removed previously, and tighten to 28 N´m (21
ft. lbs.).(3) Connect the electrical connector.
(4) Adjust the door as necessary. (Refer to 23 -
BODY/DOORS - REAR/DOOR - ADJUSTMENTS)
ADJUSTMENTS
ADJUSTMENT
NOTE: For vehicles equipped with four doors, it is
recommended that you adjust the rear door before
adjusting the front door.
²Door adjustment measurements should be
taken from stationary or welded body panels like
the roof, rocker or quarter panels.
²During adjustment procedures, it is recom-
mended that all the hinge fasteners be loosened
except for the upper most fasteners. Adjustments
can be made using the upper fasteners to hold the
door with final torque of the fasteners occurring
after correct door positioning is achieved.
23 - 28 DOORS - REARDR

REAR VIEW MIRROR
REMOVAL
(1) If equipped, disconnect mirror harness connec-
tor.
(2) Loosen the mirror base setscrew (Fig. 18).
(3) Slide the mirror base upward and off the
bracket.
INSTALLATION
INSTALLATION
(1) Position the mirror base at the bracket and
slide it downward onto the support bracket (Fig. 18).
(2) Tighten the setscrew 1 N´m (15 in. lbs.) torque.
(3) If equipped, connect mirror harness connector.
INSTALLATION - REARVIEW MIRROR
SUPPORT BRACKET
(1) Mark the position for the mirror bracket on the
outside of the windshield glass with a wax pencil.
(2) Clean the bracket contact area on the glass.
Use a mild powdered cleanser on a cloth saturated
with isopropyl (rubbing) alcohol. Finally, clean the
glass with a paper towel dampened with alcohol.
(3) Sand the surface on the support bracket with
fine grit-sandpaper. Wipe the bracket surface clean
with a paper towel.(4) Apply accelerator to the surface on the bracket
according to the following instructions:
(a) Crush the vial to saturate the felt applicator.
(b) Remove the paper sleeve.
(c) Apply accelerator to the contact surface on
the bracket.
(d) Allow the accelerator to dry for five minutes.
(e) Do not touch the bracket contact surface
after the accelerator has been applied.
(5) Apply adhesive accelerator to the bracket con-
tact surface on the windshield glass. Allow the accel-
erator to dry for one minute. Do not touch the glass
contact surface after the accelerator has been
applied.
(6) Install the bracket according to the following
instructions:
(a) Apply one drop of adhesive at the center of
the bracket contact-surface on the windshield
glass.
(b) Apply an even coat of adhesive to the contact
surface on the bracket.
(c) Align the bracket with the marked position
on the windshield glass.
(d) Press and hold the bracket in place for at
least one minute.
NOTE: Verify that the mirror support bracket is cor-
rectly aligned, because the adhesive will cure rap-
idly.
(7) Allow the adhesive to cure for 8-10 minutes.
Remove any excess adhesive with an alcohol-damp-
ened cloth.
(8) Allow the adhesive to cure for an additional
8-10 minutes before installing the mirror.
SUN VISOR
REMOVAL
(1) Remove the screws at the visor pivot and
remove the visor.
INSTALLATION
(1) Install the visor and install the screws at the
visor pivots.
Fig. 18 REAR VIEW MIRROR
1 - CONNECTOR
2 - SCREW
3 - REAR VIEW MIRROR
4 - SUPPORT BUTTON
5 - WINDSHIELD
DRINTERIOR 23 - 71

SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
A/C COMPRESSOR
CLUTCH PLATE NUT14.4 10.5 127.4
A/C COMPRESOR LINE
MANIFOLD FASTENER28 ( 6) 21 ( 4) 250 ( 50)
A/C COMPRESSOR TO
MOUNTING BRACKET
BOLTS27 20 239
ACCUMULATOR
RETAINING BOLT5 3.7 44
BLEND DOOR ACTUATOR
SCREWS2.4 ( .34) 1.8 ( .25) 21 ( 3)
HVAC HOUSING SCREWS 2.4 ( .34) 1.8 ( .25) 21 ( 3)
HVAC HOUSING TO DASH
PANEL NUTS6.2 4.6 55
SUCTION LINE TO
ACCUMULATOR FITTING9 6.6 80
24 - 8 HEATING & AIR CONDITIONINGDR
HEATING & AIR CONDITIONING (Continued)

seconds. Refer to Electronic Control Modules for
more information on the JTEC controls.
DIAGNOSIS AND TESTING - A/C COMPRESSOR
CLUTCH COIL
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information). The battery must
be fully-charged before performing the following
tests. Refer to Battery for more information.
(1) Connect an ammeter (0 to 10 ampere scale) in
series with the clutch coil terminal. Use a voltmeter
(0 to 20 volt scale) with clip-type leads for measuring
the voltage across the battery and the compressor
clutch coil.
(2) With the A/C Heater mode control switch in
any A/C mode, and the blower motor switch in the
lowest speed position, start the engine and run it at
normal idle.
(3) The compressor clutch coil voltage should read
within 0.2 volts of the battery voltage. If there is
voltage at the clutch coil, but the reading is not
within 0.2 volts of the battery voltage, test the clutch
coil feed circuit for excessive voltage drop and repair
as required. If there is no voltage reading at the
clutch coil, use a DRB IIItscan tool and (Refer to
Appropriate Diagnostic Information) for testing of the
compressor clutch circuit and PCM control. The fol-
lowing components must be checked and repaired as
required before you can complete testing of the clutch
coil:
²Fuses in the junction block and the Power Dis-
tribution Center (PDC)
²A/C heater mode control switch
²Compressor clutch relay
²A/C high pressure transducer switch²JTEC
(4) The compressor clutch coil is acceptable if the
current draw measured at the clutch coil is 2.0 to 3.9
amperes with the electrical system voltage at 11.5 to
12.5 volts. This should only be checked with the work
area temperature at 21É C (70É F). If system voltage
is more than 12.5 volts, add electrical loads by turn-
ing on electrical accessories until the system voltage
drops below 12.5 volts.
(a) If the clutch coil current reading is four
amperes or more, the coil is shorted and should be
replaced.
(b) If the clutch coil current reading is zero, the
coil is open and should be replaced.
STANDARD PROCEDURE - A/C COMPRESSOR
CLUTCH BREAK-IN
After a new compressor clutch has been installed,
cycle the compressor clutch approximately twenty
times (five seconds on, then five seconds off). During
this procedure, set the A/C Heater control to the
Recirculation Mode, the blower motor switch in the
highest speed position, and the engine speed at 1500
to 2000 rpm. This procedure (burnishing) will seat
the opposing friction surfaces and provide a higher
compressor clutch torque capability.
REMOVAL
The refrigerant system can remain fully-charged
during compressor clutch, rotor, or coil replacement.
The compressor clutch can be serviced in the vehicle.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the serpentine drive belt(Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Unplug the compressor clutch coil wire harness
connector.
(4) Remove the bolts that secure the compressor to
the mounting bracket.
(5) Remove the compressor from the mounting
bracket. Support the compressor in the engine com-
partment while servicing the clutch.
(6) Insert the two pins of the spanner wrench
(Special Tool C-4489 or equivalent) into the holes of
the clutch plate. Hold the clutch plate stationary and
remove the hex nut (Fig. 2).
(7) Remove the clutch plate.
(8) Remove the compressor clutch shims.
(9) Remove the external front housing snap ring
with snap ring pliers (Fig. 3).
(10)
Install the lip of the rotor puller (Special Tool
C-6141-1 or equivalent) into the snap ring groove
exposed in the previous step, and install the shaft pro-
tector (Special Tool C-6141-2 or equivalent) (Fig. 4).
Fig. 1 COMPRESSOR CLUTCH - TYPICAL
1 - CLUTCH PLATE
2 - SHAFT KEY (not used on KJ)
3 - ROTOR
4 - COIL
5 - CLUTCH SHIMS
6 - SNAP RING
7 - SNAP RING
24 - 10 CONTROLSDR
A/C COMPRESSOR CLUTCH (Continued)

CAUTION
SERVICE CAUTIONS
CAUTION: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions supplied
with the service equipment being used.
Never add R-12 to a refrigerant system designed to
use R-134a. Damage to the system will result.
R-12 refrigerant oil must not be mixed with R-134a
refrigerant oil. They are not compatible.
Do not use R-12 equipment or parts on the R-134a
system. Damage to the system will result.
Do not overcharge the refrigerant system. This will
cause excessive compressor head pressure and
can cause noise and system failure.
Recover the refrigerant before opening any fitting
or connection. Open the fittings with caution, even
after the system has been discharged. Never open
or loosen a connection before recovering the refrig-
erant.
Do not remove the secondary retention clip from
any spring-lock coupler connection while the refrig-
erant system is under pressure. Recover the refrig-
erant before removing the secondary retention clip.
Open the fittings with caution, even after the sys-
tem has been discharged. Never open or loosen a
connection before recovering the refrigerant.
The refrigerant system must always be evacuated
before charging.
Do not open the refrigerant system or uncap a
replacement component until you are ready to ser-
vice the system. This will prevent contamination in
the system.
Before disconnecting a component, clean the out-
side of the fittings thoroughly to prevent contami-
nation from entering the refrigerant system.
Immediately after disconnecting a component from
the refrigerant system, seal the open fittings with a
cap or plug.
Before connecting an open refrigerant fitting,
always install a new seal or gasket. Coat the fitting
and seal with clean refrigerant oil before connect-
ing.
Do not remove the sealing caps from a replacement
component until it is to be installed.
When installing a refrigerant line, avoid sharp
bends that may restrict refrigerant flow. Position the
refrigerant lines away from exhaust system compo-
nents or any sharp edges, which may damage the
line.
Tighten refrigerant fittings only to the specified
torque. The aluminum fittings used in the refriger-
ant system will not tolerate overtightening.
When disconnecting a refrigerant fitting, use a
wrench on both halves of the fitting. This will pre-vent twisting of the refrigerant lines or tubes.
Refrigerant oil will absorb moisture from the atmo-
sphere if left uncapped. Do not open a container of
refrigerant oil until you are ready to use it. Replace
the cap on the oil container immediately after using.
Store refrigerant oil only in a clean, airtight, and
moisture-free container.
Keep service tools and the work area clean. Con-
tamination of the refrigerant system through care-
less work habits must be avoided.
CAUTION - REFRIGERANT HOSES/LINES/
TUBES PRECAUTIONS
Kinks or sharp bends in the refrigerant plumbing
will reduce the capacity of the entire system. High
pressures are produced in the system when it is oper-
ating. Extreme care must be exercised to make sure
that all refrigerant system connections are pressure
tight.
A good rule for the flexible hose refrigerant lines is
to keep the radius of all bends at least ten times the
diameter of the hose. Sharp bends will reduce the
flow of refrigerant. The flexible hose lines should be
routed so they are at least 80 millimeters (3 inches)
from the exhaust manifold. It is a good practice to
inspect all flexible refrigerant system hose lines at
least once a year to make sure they are in good con-
dition and properly routed.
There are two types of refrigerant fittings:
²All fittings with O-rings need to be coated with
refrigerant oil before installation. Use only O-rings
that are the correct size and approved for use with
R-134a refrigerant. Failure to do so may result in a
leak.
²Unified plumbing connections with gaskets can-
not be serviced with O-rings. The gaskets are not
reusable and new gaskets do not require lubrication
before installing.
Using the proper tools when making a refrigerant
plumbing connection is very important. Improper
tools or improper use of the tools can damage the
refrigerant fittings. Always use two wrenches when
loosening or tightening tube fittings. Use one wrench
to hold one side of the connection stationary, while
loosening or tightening the other side of the connec-
tion with a second wrench.
The refrigerant must be recovered completely from
the system before opening any fitting or connection.
Open the fittings with caution, even after the refrig-
erant has been recovered. If any pressure is noticed
as a fitting is loosened, tighten the fitting and
recover the refrigerant from the system again.
Do not discharge refrigerant into the atmosphere.
Use an R-134a refrigerant recovery/recycling device
that meets SAE Standard J2210.
DRPLUMBING 24 - 33
PLUMBING (Continued)

INSTALLATION
INSTALLATION
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)
The compressor may be removed and repositioned
without disconnecting the refrigerant lines or dis-
charging the refrigerant system. Discharging is not
necessary if servicing the compressor clutch or clutch
coil, the engine, the cylinder head, or the generator.
NOTE: If a replacement compressor is being
installed, be certain to check the refrigerant oil
level. (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT OIL - STANDARD PRO-
CEDURE - REFRIGERANT OIL LEVEL) Use only
refrigerant oil of the type recommended for the
compressor in the vehicle. (Refer to 24 - HEATING &AIR CONDITIONING/PLUMBING/REFRIGERANT OIL -
DESCRIPTION)
(1) Install the compressor to the mounting bracket.
(2) On the 3.7L, 4.7L, 5.7L and 8.0L gasoline
engines install and tighten the bolts in the following
sequence (Fig. 4):
²The number one bolt (rear) is hand tightened
first then tightened to 55 N´m (41 ft. lbs.)
²The number three bolt is then hand tightened
and torqued to 40 N´m ( 30 ft. lbs.)
²The number two bolt is also hand tightened and
torqued to 55 N´m ( 41 ft. lbs.)
(3) Remove the tape or plugs from all of the
opened refrigerant line fittings. Install the suction
and discharge line manifold to the compressor.
Tighten the fastener to 28 N´m (250 in. lbs.).(Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
SUCTION LINE - INSTALLATION) (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - INSTALLATION)
(4) Install the serpentine drive belt(Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(5) Plug in the compressor clutch coil wire harness
connector.
(6) Connect the battery negative cable.
Fig. 3 COMPRESSOR REMOVE/INSTALL - DIESEL
ENGINE
1 - ENGINE
2 - BRACKET
3 - A/C COMPRESSOR
4 - BOLTS
Fig. 4 A/C COMPRESSOR - 3.7L ENGINE- (typical
4.7, 5.7 & 8.0L)
1 - COMPRESSOR BOLT #1
2 - COMPRESSOR BOLT #2
3 - COMPRESSOR BOLT #3
4 - A/C COMPRESSOR
5 - A/C COMPRESSOR CLUTCH AND PULLEY
6 - COMPRESSOR MOUNT
24 - 38 PLUMBINGDR
A/C COMPRESSOR (Continued)