group 13 DODGE RAM 2003 Service Workshop Manual

(9) Remove the oil pump valve retainers and asso-
ciated valve and spring one at a time (Fig. 102) (Fig.
103). Mark the combination of components as a
group and tag them as to the location from which
they were removed.
CLEANING
Clean pump and support components with solvent
and dry them with compressed air.
INSPECTION
Check condition of the seal rings and thrust
washer on the reaction shaft support. The seal rings
do not need to be replaced unless cracked, broken, or
severely worn.
Inspect the pump and support components. Replace
the pump or support if the seal ring grooves or
machined surfaces are worn, scored, pitted, or dam-
aged. Replace the pump gears if pitted, worn
chipped, or damaged.
Inspect the pump reaction shaft support bushings.
Replace either bushing only if heavily worn, scored or
damaged. It is not necessary to replace the bushings
unless they are actually damaged.
Inspect the valves and plugs for scratches, burrs,
nicks, or scores. Minor surface scratches on steel
valves and plugs can be removed with crocus clothbutdo not round off the edges of the valve or
plug lands.Maintaining sharpness of these edges is
vitally important. The edges prevent foreign matter
from lodging between the valves and plugs and the
bore.
Inspect all the valve and plug bores in the oil
pump cover. Use a penlight to view the bore interi-
ors. Replace the oil pump if any bores are distorted
or scored. Inspect all of the valve springs. The
springs must be free of distortion, warpage or broken
coils.
Trial fit each valve and plug in its bore to check
freedom of operation. When clean and dry, the valves
and plugs should drop freely into the bores.
ASSEMBLY
(1) Clean and inspect all components. Make sure
that all passages are thoroughly cleaned and are free
from dirt or debris. Make sure that all valves move
freely in their proper bore. Make sure that all gear
pockets and bushings are free from excessive wear
and scoring. Replace the oil pump if any excessive
wear or scoring is found.
(2) Coat the gears with MopartATF +4 and install
into their original locations.
(3) Lubricate the oil pump valves with Mopart
ATF +4 and install the valve, spring and retainer
Fig. 102 Oil Pump Valve Body
1 - T/C REGULATOR VALVE
2 - T/C LIMIT VALVE
3 - REGULATOR VALVE
4 - OIL PUMP VALVE BODY
Fig. 103 T/C Switch Valve
1 - RETAINER
2 - T/C SWITCH VALVE
3 - OIL PUMP VALVE BODY
21 - 566 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
OIL PUMP (Continued)

VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-
cle. For hoisting recommendations (Refer to LUBRI-
CATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE).
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
leak area. If the hose cannot be positioned without
being held, have someone help do the water test.
Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
DIAGNOSIS AND TESTING - WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be airtight in normal
driving conditions. Moving sealing surfaces will not
always seal airtight under all conditions. At times,
side glass or door seals will allow wind noise to be
noticed in the passenger compartment during high
cross winds. Over compensating on door or glass
adjustments to stop wind noise that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After a repair pro-
cedure has been performed, test vehicle to verify
noise has stopped before returning vehicle to use.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and
body components are aligned and sealed. If compo-
nent alignment or sealing is necessary, refer to the
appropriate section of this group for proper proce-
dures.
23 - 2 BODYDR
BODY (Continued)

ROAD TESTING WIND NOISE
(1) Drive the vehicle to verify the general location
of the wind noise.
(2) Apply 50 mm (2 in.) masking tape in 150 mm
(6 in.) lengths along weatherstrips, weld seams or
moldings. After each length is applied, drive the vehi-
cle. If noise goes away after a piece of tape is applied,
remove tape, locate, and repair defect.
POSSIBLE CAUSE OF WIND NOISE
²Moldings standing away from body surface can
catch wind and whistle.
²Gaps in sealed areas behind overhanging body
flanges can cause wind-rushing sounds.
²Misaligned movable components.
²Missing or improperly installed plugs in pillars.
²Weld burn through holes.
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY LUBRICATION
All mechanisms and linkages should be lubricated
when necessary. This will maintain ease of operation
and provide protection against rust and excessive
wear. The weatherstrip seals should be lubricated to
prolong their life as well as to improve door sealing.
All applicable exterior and interior vehicle operat-
ing mechanisms should be inspected and cleaned.
Pivot/sliding contact areas on the mechanisms should
then be lubricated.
(1) When necessary, lubricate the operating mech-
anisms with the specified lubricants.
(2) Apply silicone lubricant to a cloth and wipe it
on door seals to avoid over-spray that can soil pas-
senger's clothing.
(3) Before applying lubricant, the component
should be wiped clean. After lubrication, any excess
lubricant should be removed.
(4) The hood latch, latch release mechanism, latch
striker, and safety latch should be lubricated period-
ically.
(5) The door lock cylinders should be lubricated
twice each year (preferably autumn and spring).
²Spray a small amount of lock cylinder lubricant
directly into the lock cylinder.
²Apply a small amount to the key and insert it
into the lock cylinder.
²Rotate it to the locked position and then back to
the unlocked position several times.
²Remove the key. Wipe the lubricant from it with
a clean cloth to avoid soiling of clothing.
STANDARD PROCEDURE - HEAT STAKING
(1) Remove trim panel.(2) Bend or move the trim panel components at
the heat staked joints. Observe the heat staked loca-
tions and/or component seams for looseness.
(3) Heat stake the components.
(a) If the heat staked or component seam loca-
tion is loose, hold the two components tightly
together and using a soldering gun with a flat tip,
melt the material securing the components
together. Do not over heat the affected area, dam-
age to the exterior of the trim panel may occur.
(b) If the heat staked material is broken or miss-
ing, use a hot glue gun to apply new material to
the area to be repaired. The panels that are being
heat staked must be held together while the apply-
ing the glue. Once the new material is in place, it
may be necessary to use a soldering gun to melt
the newly applied material. Do not over heat the
affected area, damage to the exterior of the trim
panel may occur.
(4) Allow the repaired area to cool and verify the
repair.
(5) Install trim panel.
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR
There are many different types of plastics used in
today's automotive environment. We group plastics in
three different categories: Rigid, Semi-Rigid, and
Flexible. Any of these plastics may require the use of
an adhesion promoter for repair. These types of plas-
tic are used extensively on DaimlerChrysler Motors
vehicles. Always follow repair material manufactur-
er's plastic identification and repair procedures.
Rigid Plastics:
Examples of rigid plastic use: Fascias, Hoods,
Doors, and other Body Panels, which include SMC,
ABS, and Polycarbonates.
Semi-Rigid Plastics:
Examples of semi-rigid plastic use: Interior Panels,
Under Hood Panels, and other Body Trim Panels.
Flexible Plastics:
Examples of flexible plastic use: Fascias, Body
Moldings, and upper and lower Fascia Covers.
Repair Procedure:
The repair procedure for all three categories of
plastics is basically the same. The one difference is
the material used for the repair. The materials must
be specific for each substrate, rigid repair material
for rigid plastic repair, semi-rigid repair material for
semi-rigid plastic repair and flexible repair material
for flexible plastic repair.
DRBODY 23 - 3
BODY (Continued)

(3) Start the engine and hold the idle at 1,000 rpm
with the compressor clutch engaged.
(4) The engine should be at operating temperature.
The doors and windows must be closed.
(5) Insert a thermometer in the driver side center
A/C (panel) outlet. Operate the engine for five min-
utes.
(6) The compressor clutch may cycle, depending
upon the ambient temperature and humidity.
(7) With the compressor clutch engaged, record the
discharge air temperature and the compressor dis-
charge pressure.(8) Compare the discharge air temperature to the
Performance Temperature and Pressure chart. If the
discharge air temperature is high, (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
DIAGNOSIS AND TESTING - REFRIGERANT SYS-
TEM LEAKS) and (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - SPECIFICATIONS -
CHARGE CAPACITY).
Performance Temperature and Pressure
Ambient Air
Temperature21É C
(70É F)27É C
(80É F)32É C
(90É F)38É C
(100É F)43É C
(110É F)
Air Temperature at
Center Panel Outlet7É C
(45É F)7É C
(45É F)13É C
(55É F)13É C
(55É F)18É C
(64É F)
Compressor Inlet
Pressure at Service
Port (low Side)138 to 207 kPa
(20 to 30 psi)172 to 241
kPa
(25 to 35 psi)207 to 276
kPa
(30 to 40 psi)241 to 310
kPa
(35 to 45 psi)276 to 345 kPa
(40 to 50 psi)
Condensor Out
Pressuree at Service
Port (High Side)1034 to 1724
kPa
(150 to 250
psi)1379 to 2068
kPa
(200 to 300
psi)1724 to 2413
kPa
(250 to 350
psi)1999 to 2689
kPa
(290 to 390
psi)2413 to 2965
kPa
(350 to 430 psi)
(9) Compare the compressor discharge pressure to
the Performance Temperature and Pressure chart. Ifthe compressor discharge pressure is high, see the
Pressure Diagnosis chart.
Pressure Diagnosis
Condition Possible Causes Correction
Constant compressor
engagement and warm air
from passenger vents.1. Low refrigerant system
charge.1. See Plumbing/Diagnosis and Testing -
Refrigerant System Leaks in this group. Test the
refrigerant system for leaks. Repair, evacuate and
charge the refrigerant system, if required.
Equal pressures, but the
compressor clutch does not
engage.1. No refrigerant in the
refrigerant system.1. See Plumbing/Diagnosis and Testing -
Refrigerant System Leaks in this group. Test the
refrigerant system for leaks. Repair, evacuate and
charge the refrigerant system, if required.
2. Faulty fuse. 2. Check the fuses in the Power Distribution
Center and the junction block. Repair the shorted
circuit or component and replace the fuses, if
required.
3. Faulty a/c compressor
clutch coil.3. See A/C Compressor/Diagnosis and Testing -
Compressor Clutch Coil in this group. Test the
compressor clutch coil and replace, if required.
DRHEATING & AIR CONDITIONING 24 - 3
HEATING & AIR CONDITIONING (Continued)

Pressure Diagnosis
Condition Possible Causes Correction
4. Faulty a/c compressor
clutch relay.4. See A/C Compressor Clutch Relay/Diagnosis
and Testing - Compressor Clutch Relay in this
group. Test the compressor clutch relay and relay
circuits. Repair the circuits or replace the relay, if
required.
5. Improperly installed or
faulty Fin Sensor.5. See Fin Sensor/Diagnosis and Testing in this
group. Reinstall or replace the Fin Sensor as
required.
6. Faulty a/c high pressure
transducer.6. See A/C High Pressure Transducer/Diagnosis
and Testing in this group. Test the a/c high
pressure transducer and replace, if required.
7. Faulty Powertrain Control
Module (PCM).7. (Refer to Appropriate Diagnostic Information).
Test the PCM and replace, if required.
Normal pressures, but A/C
Performance Test air
temperatures at center panel
outlet are too high.1. Excessive refrigerant oil in
system.1. See Refrigerant Oil/Standard Procedure -
Refrigerant Oil Level in this group. Recover the
refrigerant from the refrigerant system and
inspect the refrigerant oil content. Restore the
refrigerant oil to the proper level, if required.
2. Blend door inoperative or
sealing improperly.2. See Blend Door in this group. Inspect the
blend door for proper operation and sealing and
correct, if required.
3. Blend door actuator faulty
or inoperative.3. Perform blend door actuator diagnosis, replace
if faulty.
The low side pressure is
normal or slightly low, and
the high side pressure is too
low.1. Low refrigerant system
charge.1. See Plumbing/Diagnosis and Testing -
Refrigerant System Leaks in this group. Test the
refrigerant system for leaks. Repair, evacuate and
charge the refrigerant system, if required.
2. Refrigerant flow through
the accumulator is restricted.2. See Accumulator in this group. Replace the
restricted accumulator, if required.
3. Refrigerant flow through
the evaporator coil is
restricted.3. See A/C Evaporator in this group. Replace the
restricted evaporator coil, if required.
4. Faulty compressor. 4. See A/C Compressor in this group. Replace
the compressor, if required.
The low side pressure is
normal or slightly high, and
the high side pressure is too
high.1. Condenser air flow
restricted.1. Check the condenser for damaged fins, foreign
objects obstructing air flow through the condenser
fins, and missing or improperly installed air seals.
Refer to Cooling for more information on air
seals. Clean, repair, or replace components as
required.
2. Inoperative cooling fan. 2. Refer to Cooling for more information. Test the
cooling fan and replace, if required.
3. Refrigerant system
overcharged.3. See Plumbing/Standard Procedure -
Refrigerant System Charge in this group. Recover
the refrigerant from the refrigerant system.
Charge the refrigerant system to the proper level,
if required.
24 - 4 HEATING & AIR CONDITIONINGDR
HEATING & AIR CONDITIONING (Continued)

Pressure Diagnosis
Condition Possible Causes Correction
4. Air in the refrigerant
system.4. See Plumbing/Diagnosis and Testing -
Refrigerant System Leaks in this group. Test the
refrigerant system for leaks. Repair, evacuate and
charge the refrigerant system, if required.
5. Engine overheating. 5. Refer to Cooling for more information. Test the
cooling system and repair, if required.
The low side pressure is too
high, and the high side
pressure is too low.1. Accessory drive belt
slipping.1. Refer to Cooling for more information. Inspect
the accessory drive belt condition and tension.
Tighten or replace the accessory drive belt, if
required.
2. Fixed orifice tube not
installed.2. See A/C Orifice Tube in this group. Replace
the liquid line, if required.
3. Faulty compressor. 3. See A/C Compressor in this group. Replace
the compressor, if required.
The low side pressure is too
low, and the high side
pressure is too high.1. Restricted refrigerant flow
through the refrigerant lines.1. See Liquid, Suction, and Discharge Line in this
group. Inspect the refrigerant lines for kinks, tight
bends or improper routing. Correct the routing or
replace the refrigerant line, if required.
2. Restricted refrigerant flow
through the fixed orifice tube.2. See A/C Orifice Tube in this group. Replace
the liquid line, if required.
3. Restricted refrigerant flow
through the condenser.3. See A/C Condenser in this group. Replace the
restricted condenser, if required.
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE
Before performing the following tests, refer to Cool-
ing for the procedures to check the engine coolant
level and flow, engine coolant reserve/recovery sys-
tem operation, accessory drive belt condition and ten-
sion, radiator air flow and the fan drive operation.
Also be certain that the accessory vacuum supply
line is connected at the engine vacuum source.
MAXIMUM HEATER OUTPUT
Engine coolant is delivered to the heater core
through two heater hoses. With the engine idling at
normal operating temperature, set the temperature
control knob in the full hot position, the mode control
switch knob in the floor position, and the blower
motor switch knob in the highest speed position.
Using a test thermometer, check the temperature of
the air being discharged at the HVAC housing floor
outlets. Compare the test thermometer reading to the
Temperature Reference chart.
Temperature Reference
Ambient Air Temperature15.5É C
(60É F)21.1É C
(70É F)26.6É C
(80É F)32.2É C
(90É F)
Minimum Air Temperature at
Floor Outlet62.2É C
(144É F)63.8É C
(147É F)65.5É C
(150É F)67.2É C
(153É F)
DRHEATING & AIR CONDITIONING 24 - 5
HEATING & AIR CONDITIONING (Continued)

If the floor outlet air temperature is too low, refer
to Cooling to check the engine coolant temperature
specifications. Both of the heater hoses should be hot
to the touch. The coolant return heater hose should
be slightly cooler than the coolant supply heater
hose. If the return hose is much cooler than the sup-
ply hose, locate and repair the engine coolant flow
obstruction in the cooling system. Refer to Cooling
for the procedures.
An alternate method of checking heater perfor-
mance is to use a DRBIIItscan tool to monitor the
engine coolant temperature. The floor outlet air tem-
perature reading should be no more than 4.5É C (40É
F) lower than the engine coolant temperature read-
ing.
OBSTRUCTED COOLANT FLOW Possible loca-
tions or causes of obstructed coolant flow:
²Faulty water pump.
²Faulty thermostat.
²Pinched or kinked heater hoses.
²Improper heater hose routing.
²Plugged heater hoses or supply and return ports
at the cooling system connections.
²A plugged heater core.If proper coolant flow through the cooling system is
verified, and heater outlet air temperature is still
low, a mechanical problem may exist.
MECHANICAL PROBLEMS Possible locations or
causes of insufficient heat:
²An obstructed cowl air intake.
²Obstructed heater system outlets.
²A faulty, obstructed or improperly installed
blend door.
²A faulty blower system.
²A faulty a/c heater control.
TEMPERATURE CONTROL
If the heater outlet air temperature cannot be
adjusted with the temperature control knob on the
a/c heater control panel, the following could require
service:
²A faulty a/c heater control.
²A faulty blend door actuator.
²A faulty, obstructed or improperly installed
blend door.
²An obstructed cowl air intake.
²The engine cooling system.
Heater Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
INSUFFICIENT HEATER
OUTPUT.1. Incorrect engine
coolant level.1. Check the engine coolant level. Refer to Cooling for
the procedures.
2. Air trapped in engine
cooling system.2. Check the operation of the coolant reserve/recovery
system. Refer to Cooling for the procedures.
3. Incorrect engine
coolant temperature.3. Check the performance and operation of the engine
cooling system including: thermostat, water pump, fan
drive, accessory drive belt, coolant flow (plugged radiator
or heater core, plugged or kinked coolant hoses), air flow
(missing or improperly installed radiator air seals or fan
shroud). Refer to Cooling for the procedures.
4. Blend door actuator
inoperative or defective.4. (Refer to Controls/Blend Door Actuator) in this group.
5. Blend door not
operating properly.5. Check for a damaged, obstructed or improperly
installed blend door or seals. (Refer to Controls/Blend
Door Actuator) in this group.
6. Insufficient air flow
through heater housing.6. Remove foreign material or obstructions from cowl air
intake.
7. Improper blower motor
operation.7. (Refer to Distribution/Blower Motor/ Diagnosis and
Testing) in this group.
24 - 6 HEATING & AIR CONDITIONINGDR
HEATING & AIR CONDITIONING (Continued)

small amount of R-12 added to an R-134a refrigerant
system will cause compressor failure, refrigerant oil
sludge or poor air conditioning system performance.
In addition, the PolyAlkylene Glycol (PAG) synthetic
refrigerant oils used in an R-134a refrigerant system
are not compatible with the mineral-based refriger-
ant oils used in an R-12 refrigerant system.
R-134a refrigerant system service ports, service
tool couplers and refrigerant dispensing bottles have
all been designed with unique fittings to ensure that
an R-134a system is not accidentally contaminated
with the wrong refrigerant (R-12). There are also
labels posted in the engine compartment of the vehi-
cle and on the compressor identifying to service tech-
nicians that the air conditioning system is equipped
with R-134a.
DIAGNOSIS AND TESTING- REFRIGERANT
SYSTEM LEAKS
WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION).
If the air conditioning system does not cool prop-
erly, the A/C system performance should be tested.
See A/C Performance in the Diagnosis and Testing
section of this group for the procedures. If the A/C
system refrigerant fill is found to be low or if the sys-
tem is empty; a leak at a refrigerant line, connector
fitting, component, or component seal is likely.
An electronic leak detector designed for R-134a
refrigerant, or a fluorescent R-134a leak detection
dye and a black light are recommended for locating
and confirming refrigerant system leaks. Refer to the
operating instructions supplied by the equipment
manufacturer for the proper care and use of this
equipment.
An oily residue on or near refrigerant system lines,
connector fittings, components, or component seals
can indicate the general location of a possible refrig-
erant leak. However, the exact leak location should
be confirmed with an electronic leak detector prior to
component repair or replacement.
To detect a leak in the refrigerant system with an
electronic leak detector, perform one of the following
procedures:
SYSTEM EMPTY
(1) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE).
(2) Connect and dispense 0.283 kilograms (0.625
pounds or 10 ounces) of R-134a refrigerant into the
evacuated refrigerant system (Refer to 24 - HEAT-ING & AIR CONDITIONING/PLUMBING/REFRIG-
ERANT - STANDARD PROCEDURE).
(3) Position the vehicle in a wind-free work area.
This will aid in detecting small leaks.
(4) With the engine not running, use a electronic
R-134a leak detector and search for leaks. Because
R-134a refrigerant is heavier than air, the leak detec-
tor probe should be moved slowly along the bottom
side of all refrigerant lines, connector fittings and
components.
(5) To inspect the evaporator coil for leaks, insert
the electronic leak detector probe into the center
instrument panel outlet and the floor duct outlet. Set
the blower motor switch to the lowest speed position,
and the mode control switch in the recirculation
mode (Max-A/C).
SYSTEM LOW
(1) Position the vehicle in a wind-free work area.
This will aid in detecting small leaks.
(2) Bring the refrigerant system up to operating
temperature and pressure. This is done by allowing
the engine to run with the air conditioning system
turned on for five minutes.
(3) With the engine not running, use a electronic
R-134a leak detector and search for leaks. Because
R-134a refrigerant is heavier than air, the leak detec-
tor probe should be moved slowly along the bottom
side of all refrigerant lines, connector fittings and
components.
(4) To inspect the evaporator coil for leaks, insert
the electronic leak detector probe into the center
instrument panel outlet and the floor duct outlet. Set
the blower motor switch to the lowest speed position,
and the mode control switch in the recirculation
mode (Max-A/C).
STANDARD PROCEDURE
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE
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.
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 could damage the compressor.
Evacuating the refrigerant system will remove the
DRPLUMBING 24 - 51
REFRIGERANT (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)

ABS - DESCRIPTION, BRAKES...........5-39
ABS - OPERATION, BRAKES.............5-39
ABS BRAKE BLEEDING - STANDARD
PROCEDURE.........................5-40
ABS INDICATOR - DESCRIPTION.........8J-17
ABS INDICATOR - OPERATION..........8J-17
A/C APPLICATION TABLE,
SPECIFICATIONS......................24-7
A/C COMPRESSOR CLUTCH -
DESCRIPTION........................24-9
A/C COMPRESSOR CLUTCH -
INSPECTION........................24-12
A/C COMPRESSOR CLUTCH -
INSTALLATION.......................24-12
A/C COMPRESSOR CLUTCH -
OPERATION..........................24-9
A/C COMPRESSOR CLUTCH - REMOVAL . . 24-10
A/C COMPRESSOR CLUTCH BREAK-IN -
STANDARD PROCEDURE...............24-10
A/C COMPRESSOR CLUTCH COIL -
DIAGNOSIS AND TESTING.............24-10
A/C COMPRESSOR CLUTCH RELAY -
DESCRIPTION.......................24-13
A/C COMPRESSOR CLUTCH RELAY -
INSTALLATION.......................24-14
A/C COMPRESSOR CLUTCH RELAY -
OPERATION.........................24-13
A/C COMPRESSOR CLUTCH RELAY -
REMOVAL..........................24-14
A/C COMPRESSOR NOISE - DIAGNOSIS
AND TESTING.......................24-36
A/C CONDENSER - DESCRIPTION.........24-39
A/C CONDENSER - OPERATION..........24-39
A/C EVAPORATOR - DESCRIPTION.......24-47
A/C EVAPORATOR - INSTALLATION......24-47
A/C EVAPORATOR - OPERATION.........24-47
A/C EVAPORATOR - REMOVAL..........24-47
A/C HEATER CONTROL - DESCRIPTION . . . 24-14
A/C HEATER CONTROL - INSTALLATION . . . 24-15
A/C HEATER CONTROL - REMOVAL......24-14
A/C ORIFICE TUBE - DESCRIPTION.......24-48
A/C ORIFICE TUBE - INSTALLATION......24-49
A/C ORIFICE TUBE - OPERATION........24-48
A/C ORIFICE TUBE - REMOVAL..........24-49
A/C PERFORMANCE - DIAGNOSIS AND
TESTING............................24-2
A/C PRESSURE TRANSDUCER -
DESCRIPTION.......................24-15
A/C PRESSURE TRANSDUCER -
DIAGNOSIS AND TESTING.............24-15
A/C PRESSURE TRANSDUCER -
INSTALLATION.......................24-16
A/C PRESSURE TRANSDUCER -
OPERATION.........................24-15
A/C PRESSURE TRANSDUCER -
REMOVAL..........................24-16
ACCELERATOR PEDAL - INSTALLATION . . . 14-24
ACCELERATOR PEDAL - REMOVAL.......14-24
ACCELERATOR PEDAL POSITION
SENSOR - DESCRIPTION...............14-25
ACCELERATOR PEDAL POSITION
SENSOR - INSTALLATION..............14-25
ACCELERATOR PEDAL POSITION
SENSOR - OPERATION................14-25
ACCELERATOR PEDAL POSITION
SENSOR - REMOVAL..................14-25
ACCESSORY DRIVE BELT - DIAGNOSIS
AND TESTING................7-25,7-28,7-31
ACCUMULATOR - DESCRIPTION.........24-49
ACCUMULATOR - DESCRIPTION
. . 21-191,21-372
ACCUMULATOR - INSPECTION
. . . 21-192,21-373
ACCUMULATOR - INSTALLATION
........24-50
ACCUMULATOR - OPERATION
..........24-49
ACCUMULATOR - OPERATION
....21-192,21-373
ACCUMULATOR - REMOVAL
............24-49
ACM COVER - INSTALLATION
............8O-9
ACM COVER - REMOVAL
...............8O-9
ACTUATION TEST MODE - DESCRIPTION,
CIRCUIT
.............................25-1
ACTUATOR - DESCRIPTION, BLEND
DOOR
.............................24-16
ACTUATOR - DESCRIPTION, FUEL
CONTROL
..........................14-85
ACTUATOR - DESCRIPTION, MODE
DOOR
.............................24-20
ACTUATOR - DESCRIPTION,
RECIRCULATION DOOR
................24-22ACTUATOR - INSTALLATION, BLEND
DOOR.............................24-17
ACTUATOR - INSTALLATION, FLOOR -
DEFROST DOOR.....................24-20
ACTUATOR - INSTALLATION, FUEL
CONTROL..........................14-85
ACTUATOR - INSTALLATION, INSIDE
HANDLE.......................23-22,23-32
ACTUATOR - INSTALLATION, MODE
DOOR.............................24-22
ACTUATOR - INSTALLATION,
RECIRCULATION DOOR................24-23
ACTUATOR - OPERATION, BLEND DOOR . . 24-16
ACTUATOR - OPERATION, FUEL
CONTROL..........................14-85
ACTUATOR - OPERATION, MODE DOOR . . . 24-21
ACTUATOR - OPERATION,
RECIRCULATION DOOR................24-22
ACTUATOR - REMOVAL, BLEND DOOR....24-17
ACTUATOR - REMOVAL, FLOOR -
DEFROST DOOR.....................24-19
ACTUATOR - REMOVAL, FUEL CONTROL . . 14-85
ACTUATOR - REMOVAL, INSIDE HANDLE . 23-22,
23-31
ACTUATOR - REMOVAL, MODE DOOR....24-21
ACTUATOR - REMOVAL, RECIRCULATION
DOOR.............................24-22
ADAPTER HOUSING SEAL -
INSTALLATION...........21-127,21-539,21-83
ADAPTER HOUSING SEAL - REMOVAL . . 21-127,
21-539,21-83
ADAPTER MOUNT - INSTALLATION, DISC
BRAKE CALIPER......................5-17
ADDING ADDITIONAL COOLANT -
STANDARD PROCEDURE................7-19
ADDITIONAL COOLANT - STANDARD
PROCEDURE, ADDING..................7-19
ADHESIVE LOCATIONS -
SPECIFICATIONS, STRUCTURAL........23-113
ADJUSTABLE PEDAL MOTOR -
DESCRIPTION........................5-24
ADJUSTABLE PEDAL MOTOR -
INSTALLATION........................5-24
ADJUSTABLE PEDAL MOTOR - REMOVAL . . 5-24
ADJUSTABLE PEDAL SWITCH -
INSTALLATION.........................5-6
ADJUSTABLE PEDAL SWITCH -
REMOVAL............................5-6
ADJUSTER - DIAGNOSIS AND TESTING,
HYDRAULIC LASH................9-124,9-31
ADJUSTER - INSTALLATION, SEAT BELT
TURNING LOOP.....................8O-50
ADJUSTER - REMOVAL, SEAT BELT
TURNING LOOP.....................8O-50
ADJUSTER ASSEMBLY - DESCRIPTION,
ROCKER ARM.......................9-124
ADJUSTER ASSEMBLY - INSTALLATION,
ROCKER ARM..................9-124,9-249
ADJUSTER ASSEMBLY - REMOVAL,
ROCKER ARM..................9-124,9-249
ADJUSTER ASSY - CLEANING, ROCKER
ARM
..............................9-310
ADJUSTER ASSY - DESCRIPTION,
ROCKER ARM
.......................9-310
ADJUSTER ASSY - INSPECTION,
ROCKER ARM
.......................9-311
ADJUSTER ASSY - INSTALLATION,
ROCKER ARM
.............9-198,9-312,9-379
ADJUSTER ASSY - REMOVAL, ROCKER
ARM
....................9-198,9-310,9-379
ADJUSTING TOOL - ADJUSTMENT, WITH
. . . 5-36
AFTER A SUPPLEMENTAL RESTRAINT
DEPLOYMENT - STANDARD
PROCEDURE, SERVICE
.................8O-7
AIR CHECKING TRANSMISSION CLUTCH
OPERATION - DIAGNOSIS AND
TESTING
..........................21-494
AIR CLEANER ELEMENT - INSTALLATION
. 9-105,
9-20,9-242,9-298,9-370
AIR CLEANER ELEMENT - REMOVAL
. 9-105,9-20,
9-242,9-297,9-370
AIR CONDITIONER - DESCRIPTION,
HEATER
.............................24-1
AIR CONDITIONER - OPERATION,
HEATER
.............................24-1
AIR CONDITIONING - INSTALLATION,
WATER PUMP BYPASS HOSE WITH
.......7-70AIR CONDITIONING - INSTALLATION,
WATER PUMP BYPASS HOSE
WITHOUT............................7-70
AIR CONDITIONING - REMOVAL, WATER
PUMP BYPASS HOSE WITH.............7-68
AIR CONDITIONING - REMOVAL, WATER
PUMP BYPASS HOSE WITHOUT..........7-69
AIR CONTROL MOTOR - DESCRIPTION,
IDLE...............................14-33
AIR CONTROL MOTOR - INSTALLATION,
IDLE...............................14-35
AIR CONTROL MOTOR - OPERATION,
IDLE...............................14-33
AIR CONTROL MOTOR - REMOVAL, IDLE . . 14-34
AIR COOLER AND PLUMBING -
CLEANING, CHARGE..................11-16
AIR COOLER AND PLUMBING -
DESCRIPTION, CHARGE...............11-15
AIR COOLER AND PLUMBING -
INSPECTION, CHARGE.................11-16
AIR COOLER AND PLUMBING -
INSTALLATION, CHARGE...............11-16
AIR COOLER AND PLUMBING -
OPERATION, CHARGE.................11-15
AIR COOLER AND PLUMBING -
REMOVAL, CHARGE..................11-15
AIR COOLER SYSTEM - LEAKS -
DIAGNOSIS AND TESTING, CHARGE......11-15
AIR DAM - INSTALLATION, FRONT........13-2
AIR DAM - REMOVAL, FRONT...........13-2
AIR HEATER - DESCRIPTION, INTAKE.....14-91
AIR HEATER - INSTALLATION, INTAKE....14-91
AIR HEATER - OPERATION, INTAKE......14-91
AIR HEATER - REMOVAL, INTAKE........14-91
AIR HEATER RELAY - DESCRIPTION,
INTAKE ............................14-92
AIR HEATER RELAY - INSTALLATION,
INTAKE ............................14-93
AIR HEATER RELAY - OPERATION,
INTAKE ............................14-92
AIR HEATER RELAY - REMOVAL, INTAKE . . 14-93
AIR INTAKE SYSTEM - INSTALLATION....9-194
AIR INTAKE SYSTEM - REMOVAL........9-194
AIR TEMPERATURE SENSOR -
DESCRIPTION, INTAKE................14-36
AIR TEMPERATURE SENSOR -
INSTALLATION, INTAKE................14-38
AIR TEMPERATURE SENSOR -
OPERATION, INTAKE..................14-36
AIR TEMPERATURE SENSOR -
REMOVAL, INTAKE...................14-36
AIR TEMPERATURE SENSOR/MAP
SENSOR - DESCRIPTION, INTAKE........14-93
AIR TEMPERATURE SENSOR/MAP
SENSOR - INSTALLATION, INTAKE.......14-94
AIR TEMPERATURE SENSOR/MAP
SENSOR - OPERATION, INTAKE.........14-93
AIR TEMPERATURE SENSOR/MAP
SENSOR - REMOVAL, INTAKE...........14-93
AIR TEMPERATURE SENSOR/PRESSURE
SENSOR - DESCRIPTION, INLET.........14-90
AIR TEMPERATURE SENSOR/PRESSURE
SENSOR - INSTALLATION, INLET........14-90
AIR TEMPERATURE SENSOR/PRESSURE
SENSOR - OPERATION, INLET..........14-90
AIR TEMPERATURE SENSOR/PRESSURE
SENSOR - REMOVAL, INLET............14-90
AIR TESTING TRANSMISSION CLUTCH
AND BAND OPERATION - DIAGNOSIS
AND TESTING................21-143,21-324
AIR TO OIL COOLER - INSTALLATION.....7-75
AIR TO OIL COOLER - REMOVAL.........7-74
AIRBAG - DESCRIPTION, DRIVER........8O-22
AIRBAG - DESCRIPTION, PASSENGER....8O-34
AIRBAG - DESCRIPTION, SIDE CURTAIN . . 8O-51
AIRBAG - INSTALLATION, DRIVER.......8O-24
AIRBAG - INSTALLATION, PASSENGER . . . 8O-37
AIRBAG - INSTALLATION, SIDE CURTAIN . . 8O-53
AIRBAG - OPERATION, DRIVER.........8O-23
AIRBAG - OPERATION, PASSENGER......8O-35
AIRBAG - OPERATION, SIDE CURTAIN....8O-51
AIRBAG - REMOVAL, DRIVER
...........8O-23
AIRBAG - REMOVAL, PASSENGER
.......8O-35
AIRBAG - REMOVAL, SIDE CURTAIN
.....8O-52
AIRBAG CONTROL MODULE -
DESCRIPTION
.......................8O-10
AIRBAG CONTROL MODULE -
DESCRIPTION, SIDE IMPACT
...........8O-53
DRINDEX 1
Description Group-Page Description Group-Page Description Group-Page