1993 DODGE TRUCK clutch

[x] Cancel search: clutch

weight key battery cruise control automatic transmission set clock timing belt

Load previous 8 pages

Page 1448 of 1502

DODGE TRUCK 1993 Service Repair Manual
HEATING
AND
AIR
CONDITIONING
24 -

TEMPERATURE
IN
TEST AREA
21-29° C
(70-85°
F)

VERIFY R-12 CHARGE-CONNECT MANIFOLD GAUGES

SEE
MAINTENANCE AND ADJUSTMENTS SECTION
IF
R-12
CHARGE
I

Page 1449 of 1502

DODGE TRUCK 1993 Service Repair Manual
24-12
HEATING
AND AIR
CONDITIONING

PERFORMANCE TEMPERATURE CHART

Garage
Ambient
Temperature
21
°C

(70°F) 26.5°C
(80°F) 32°C
(90°F) 3/.5°'J
(100T) 43°C
(110°F)

Dis

24-12
HEATING
AND AIR
CONDITIONING

PERFORMANCE TEMPERATURE CHART

Garage
Ambient
Temperature
21
°C

(70°F) 26.5°C
(80°F) 32°C
(90°F) 3/.5°'J
(100T) 43°C
(110°F)

Discharge
Air Temperature
3-10°C
(38-50°F) 6-12°C
(42-54'F) 8-14°C
(46-58°F) 10-17°C
(50-62°F) 12-19°C
(54-66°F)

Compressor
Discharge Pressure
1344 a
1620 a
1861 kPag 2103 a 1379kPcg
2344 a

Compressor
Discharge Pressure

120 •
195 PS'9 160 .
235 PS'9 200 .
270 PS'9 240 .
305 PS'9 280 .
340 PS'9

Evaporator
Suction Pressure
124 kPag
207 a 138 kPag
241 J 269 kPag III kP°9
296 179 ,D
324 kPag

Evaporator
Suction Pressure

18 .
30 PS'9 20 .
35 pS'g 22
39 pS,g
25 .
43 pS'g 26 .
47 pS'9
J9124-97 pressure must drop to below -50 kPag (15 inch of vacu

um).
If the condition is not met the H-valve is stuck
open and should be replaced. Remove Liquid C02 and
watch evaporator suction pressure; it should increase to a minimum of 262 kPag (38 psig) and then stabilize to a
pressure of 172-240 kPag (25-35 psig). Any H-valve
which does not produce this response is stuck open and should be replaced.
(4) Connect A/C water valve vacuum hose (gray)
and set temperature control in cool position.
(5) Set engine speed at 1,000 RPM and blower on

HI.
The evaporator suction pressure should be in the
range of 138-207 kPag (20-30 psig). If compressor dis charge is higher than 1 656 kPag (240 psig), check
for restricted discharge line, radiator overheating, air in system or faulty viscous fan drive. If discharge
pressure is less than 966 kPag (140 psig), check com
pressor head gaskets and discharge reeds.
(6) Connect the electrical wires to the electronic
temperature cycling clutch switch.
VACUUM CONTROL SYSTEM ADJUSTMENTS
AND TESTS To keep the vacuum harness in place, common vi
nyl tape (sometimes called plastic tape of electri
cian's tape) cannot be used. It will cause the tube to
deteriorate directly under the tape, when high under
hood temperatures are involved. A compatible nylon type of tape such as MS CH69 (#281) or an equivalent must be used.
The test of the push button switch operation deter
mines whether or not the vacuum and electrical cir cuits are properly connected and the controls are
functioning properly. However, it is possible that this system operating perfectly at engine idle during high
manifold vacuum, may not function properly at high engine speeds. Before starting this test, stop engine and make certain the vacuum source hose at engine
intake manifold is tight on its connector.
EXPANSION (H) VALVE TEST
Test must be made at ambient temperature of
21°C-29°C (70°F-85°F).
After performing all previously mentioned tests,
conduct the H-valve test as follows:
(1) Operate the engine at 1,000 RPM with the win
dows closed. Set air conditioning controls for MAX
A/C,
high blower, temperature control lever in full
reheat position and cycling clutch switch electrically
bypassed. Disconnect and plug the water valve vac uum hose in the engine compartment. (2) Operate the system for at least 5 minutes in or
der to obtain partial stabilization and sufficient re
heat to load the system. Pressure at the discharge service port should reach 966-1 656 kPag (140-240
psig) (Fig. 6). If head pressure of 966-1 656 kPag (140-240 psig) cannot be obtained, check system
charge level.

Fig.
6
Expansion
(H)
Valve
Test

WARNING:
EXTREME
CARE
MUST
BE
USED
WHEN
HANDLING
LIQUID
C02 AS
SKIN
INJURY
CAN OC

CUR
IF
PROTECTIVE
GLOVES
ARE NOT
WORN.
(3) Put Liquid C02 on control head (completely cover
head) for a minimum of 30 seconds. Evaporator suction

Page 1451 of 1502

DODGE TRUCK 1993 Service Repair Manual
24 - 14
HEATING
AND AIR
CONDITIONING

•

Fig.
9
Vacuum
Actuator Test terfere with the proper operation of the air
conditioning and heating controls at high speeds and
during acceleration

24 - 14
HEATING
AND AIR
CONDITIONING

•

Fig.
9
Vacuum
Actuator Test terfere with the proper operation of the air
conditioning and heating controls at high speeds and
during acceleration.
COMPRESSOR NOISE Noises that develop during air conditioning opera
tion can often be misleading.
FOR EXAMPLE: What sounds like a failed front
bearing or connecting rod, may be caused by loose

bolts,
nuts, mounting brackets or a loose clutch as sembly.
Improper belt tension is also often the source of an
objectionable noise and can easily be mistaken for in
ternal compressor troubles.
Drive belts are speed sensitive. That is, at different
engine speeds, and depending upon belt tension, belts
can develop unusual noises that are often mistaken
for mechanical problems within the compressor.
The adjustment procedures follows: (1) Select a quiet area for testing. Switch compres
sor on and off several times to clearly identify com
pressor noise. (2) Tighten all compressor mounting bolts, clutch
mounting bolt, clutch coil mounting screws and com
pressor drive belts. Check that plumbing is not rub
bing other parts. (3) Make sure that matched drive belts are in
equal tension. Replace any parts that are defective or
missing.
(4) Test the vehicle. If noise persists, continue
trouble shooting system for source of noise. Refer to A/C Compressor and Clutch Diagnosis
Charts.

CLUTCH COIL
TEST
(1) Verify battery state of charge (test indicator
should be green.)
(2) Connect an ammeter (0-10 ampere scale) in se
ries with the clutch coil terminal. Use a voltmeter (0-20 volt scale) with clip leads measuring voltage
across the battery and A/C clutch.
(3) With A/C control in A/C mode and blower at
low speed, start the engine and run at normal idle.
(4) The A/C clutch should engage in 11 seconds af
ter the start. The clutch voltage should be within 2
volts of the battery voltage. If the A/C clutch does not engage, check the fuse.
(5) The A/C coil is acceptable, if the current draw
is 2.0 to 3.7 amperes at 11.5 to 12.5 volts. The test
room temperature should be 18°C to 24°C (65°F to
75°F).
Where voltage is more than 12.5 volts, add
electrical loads as needed by increasing blower speed
and/or switching other electrical accessories on. If
coil current reads zero, the coil is open and should be
replaced. If the ammeter reading is 4 amperes or more, the coil is shorted and should be replaced. If
the coil voltage is not within 2 volts of the battery
voltage, check the circuit external to the clutch coil for excessive voltage drop and repair accordingly.
Refer to A/C Compressor and Clutch Diagnosis
Charts.

Page 1452 of 1502

DODGE TRUCK 1993 Service Repair Manual
HEATING
AND AIR
CONDITIONING
24 -
A/C COMPRESSOR AND CLUTCH DIAGNOSIS

A/C
COMPRESSOR NOISY

?

COMPRESSOR
OFF
COMPRESSOR
ON

I

CLUTCH PULLEY
RUBBING
EVALUATE INSIDE
VEHICLE MODE-

Page 1453 of 1502

DODGE TRUCK 1993 Service Repair Manual
24 - 16 HEATING AND AIR CONDITIONING

A/C
COMPRESSOR AND CLUTCH DIAGNOSIS (CONT.)

COMPRESSOR
CLUTCH
WON'T
ENGAGE

f
f

NO
VOLTAGE
VOLTAGE
AT
AT CLUTCH CLUTCH
NORMAL

f t
O

Page 1457 of 1502

DODGE TRUCK 1993 Service Repair Manual
24
- 20
HEATING
AND AIR
CONDITIONING

• (3) Turn
3
refrigerant manifold valves completely
clockwise
to
puncture
the
cans
and
close
the
mani
fold valves.
(4) Purge
the air
from

24
- 20
HEATING
AND AIR
CONDITIONING

• (3) Turn
3
refrigerant manifold valves completely
clockwise
to
puncture
the
cans
and
close
the
mani
fold valves.
(4) Purge
the air
from
the
charging line
by
loosen
ing
the
charging hose
at the
manifold gauge
set and

turn
one of the
refrigerant valves counterclockwise. When
the
refrigerant
gas
starts escaping from
the

loose connection, tighten
the
hose.
(5) Fully open
all 3
refrigerant manifold valves
and place
the
cans
of
refrigerant into
a pan
contain
ing 52°C (125°F) water.
The
water will warm
the

charging
can and aid in the
transfer
of the
charge
into
the
system.
(6) Start
the
engine
and
move
the
controls
to A/C

low blower position.
The electronic temperature cycling switch will pre
vent
the
clutch from engaging until refrigerant
is
added
to the
system.
If the
clutch does engage,
re

place
the
switch before proceeding
any
further. (7) Charge through
the
suction side
of the
system
by slowly opening
the
suction manifold valve. Adjust
the valve
as
necessary
so
charging pressure does
not
exceed
345
kPag
(50
psig). Maintain
the
temperature
of
the
water
in the pan by
adding warm water
as

necessary. (8) Adjust
the
engine speed
to a
fast idle
of
approx
imately
1,300 RPM.
(9) When
all 3
cans
of
refrigerant
are
completely
empty, close
the
manifold gauge
set
valves
and re

frigerant manifold valves. The maximum refrigerant charge
is 44 oz.

REFRIGERANT
LEAK REPAIR PROCEDURE

LOST CHARGE If
the
system
has
lost
all
charge
due to a
leak: (1) Evacuate
the
system.
(2) Charge
the
system with approximately
1
pound
of refrigerant. (3) Locate
all
leaks.
(4) Repair
all
leaks.
(5) Replace filter-drier bottle.

CAUTION:
Replacement
filter-drier
units
must
be

sealed
while
in
storage.
The
drier
used
in
these

units
absorbs
and
traps
moisture
quickly
upon
ex

posure
to the
atmosphere.
When
installing
a
drier,

have
all
tools
and
supplies ready
for
quick
reas

sembly
to
avoid keeping
the
system open
any
longer
than
necessary.

(6) Check system
oil
level. (7) Evacuate
and
charge
the
system.
LOW CHARGE If
the
system
has not
lost
all of its
refrigerant
charge; locate
and
repair
all
leaks.
If it is
necessary
to increase
the
system pressure
to
find
the
leak
(be
cause
of an
especially
low
charge),
add 230 g (1/2 lb)

of refrigerant.
If
there
has
been
a
significant
oil
loss,
check
the
system
oil
level.
If
leak repair
was
possible
without discharging system
and an oil
level check
was
not
necessary,
use
procedure
for
correcting
low

refrigerant level.

CORRECTING
LOW
REFRIGERANT LEVEL
Since
the
refrigeration system
is
completely sealed,
the refrigerant level will
not be low
unless there
is a
leak
in the
system. Before adding refrigerant where
the
cause
of a low

level
is not
known,
the
system should
be
tested
for

leaks.
Assuming that leaks have been corrected without
discharging
the
system, proceed with partial charge.
Install
and
connect manifold gauge
set.
(1) Close both manifold gauge
set
valves. Open
manifold gauge
set
needle valve.
(2) Connect
the
suction gauge test hose
to the
suc
tion service port
of the
compressor. Connect
the
dis charge gauge test hose
to the
discharge service port. (3) Connect
an end of
long test hose
to the
center
manifold outlet,
and
other
end to
refrigerant dispens ing manifold. (4) Close
the 2
dispensing manifold valves
and

open remaining dispensing manifold valve. Remove
protective
cap
from opened valve.

WARNING: NEVER
USE
THESE CANS
TO
CHARGE
INTO
THE
HIGH
PRESSURE SIDE
OF
THE
SYSTEM

(COMPRESSOR
DISCHARGE
PORT)
OR
INTO
A
SYSTEM
THAT
IS AT
HIGH
TEMPERATURE.
THE
HIGH
SYSTEM PRESSURES COULD
BE
TRANS
FERRED
INTO
THE
CHARGING
CAN
CAUSING
IT

TO EXPLODE.

(5) Screw
a can of R-12 to the
opened manifold
valve.
Be
sure gasket
is in
place
and in
good condi
tion. Tighten refrigerant
can and
manifold locking nut
to
ensure
a
good seal.
Do not
overtighten.
Tighten
to 9.5 N*m (7 ft. lbs.)
torque,
if
gasket
is in
good condition.
(6) Turn manifold valve (above
the
refrigerant
can)

completely clockwise
to
puncture
the can.
This closes
the valve
and
seals
the
refrigerant
in the can.

CAUTION:
Do not
heat refrigerant
12
above
52°C

(125°F).

(7) Place refrigerant
can in a
large
pan of
water
heated
to
52°C (125°F). Place
pan of
water containing
the refrigerant
can on an
accurate scale
so the
amount
of
refrigerant added
can be
weighed. Open
the refrigerant manifold valve.
(8) Purge
all air
from test hoses.
Air in the
system
will
be
trapped
in the
condenser causing abnormally
high discharge pressures
and
interfering with con densing
of the
refrigerant.

Page 1458 of 1502

DODGE TRUCK 1993 Service Repair Manual
•

HEATING
AND AIR
CONDITIONING
24 - 21 (a) Loosen both test hoses at the manifold gauge
set. Tighten the hoses as soon as the air is purged. (b) Loosen charging hose connection at manifold

•

HEATING
AND AIR
CONDITIONING
24 - 21 (a) Loosen both test hoses at the manifold gauge
set. Tighten the hoses as soon as the air is purged. (b) Loosen charging hose connection at manifold
gauge set. This will purge air from the charging

hose.
Tighten connection as soon as air is purged.
(9) With vehicle windows open and hood up, oper
ate engine at 1,300 RPM. (10) Place air conditioner control on A/C and place
the fan switch on high. (11) If necessary, block the condenser to maintain
a discharge pressure of 1 550-1 725 kPag (225-250

psig).
System must be charged through the evapora
tor suction service ports as follows:
(a) Slowly open the suction service gauge valve.
Meter flow of refrigerant by adjusting the suction service gauge valve so the pressure registered at
the suction service gauge does not exceed 345 kPag

COMPRESSOR
J
(50
psig). Keep refrigerant container upright.
(b) Add refrigerant gas until there is no foam visi
ble at the sight glass. As soon as all foam clears, note the weight registered on the refrigerant scale.
(c) Watch the refrigerant weighing scale and add
437 g (14 oz.) of refrigerant (equivalent to 1 can).
(d) Close the suction gauge valve.

CAUTION:
TOO
much
refrigerant
in the
system
can

cause
abnormally high discharge pressures. Care
must
be
used
so the
exact recommended amount
of
refrigerant
is
added
after
foam clears
in the
sight

glass.

(e) Close dispensing manifold valve. Remove test
hoses and adapters from the service ports of com
pressor and install protective caps at service ports.

RVICE (SD-709)

INDEX

page

Compressor
21

Compressor
Shaft Seal
.................... 25
The A/C system uses a 7 piston design Sanden SD-
709 compressor. Designated the SD-709, the compres
sor is mounted on the front right side of the engine
and is driven by a serpentine belt.
System lubrication is provided by 135cc ±15cc (4.6
cu. in. ±0.5 cu. in.) of 500 viscosity refrigerant oil.
The clutch used on the compressor consists of 3 ba
sic components:
(1) The pulley.
(2) The front plate. (3) The field coil.
The pulley and field coil are attached to the front
head of the compressor with snap rings. The hub is keyed to the compressor shaft and is retained on the
shaft with a self-locking nut. Special service tools are
required to remove and install the clutch plate on
the compressor shaft.

COMPRESSOR
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Disconnect the clutch lead wire.
(3) Remove the discharge and inlet (suction) ser
vice valves from the compressor. Plug or tape all the
openings.
(4) Refer to Group 7, Cooling System and remove
the drive belt(s). (5) Remove the bolts and lift the compressor from
the mounting bracket (Fig. 1).
page

Cylinder Head
/
Valve Plate
27
Magnetic
Clutch
22

Fig.
1
Compressor
Mounting

INSTALLATION
If a replacement compressor is being installed,
check the oil level. Add or subtract oil as necessary.
Install the magnetic clutch on the compressor.
(1) Install the compressor on the mounting bracket.
Tighten the bolts to 27 N*m (20 ft. lbs.) torque.
(2) Refer to Group 7, Cooling System and install
the drive belt(s).
(3) Check the belt tension.
@ New drive belt-800-900 N (180-200 lbs-f).
• Used belt-623-712 N (140-160 lbs-f).

Page 1459 of 1502

DODGE TRUCK 1993 Service Repair Manual
24 - 22
HEATING
AND AIR
CONDITIONING

•
(4)
Remove the tape or plastic plugs from all the
suction and discharge openings and install the ser
vice valves on the compressor.

(5)
Connect t

Load next 8 pages

Page: < prev 1-10 ... 281-288 289-296 297-304 305-312 313-320 321-328 329-336 next >

checking oil engine coolant dashboard warning lights overheating airbag brake fluid