1998 DODGE RAM 1500 Drive belt removal

(8) Install the left a-pillar trim. (Refer to 23 -
BODY/INTERIOR/A-PILLAR TRIM - INSTALLA-
TION)
(9) Position the left end cap and seat the attach-
ment clips fully.
(10) Install the right side mounting bolts on the
a-pillar and one right mounting bolt on the cowl side
panel and tighten to 12 N´m (9 ft. lbs.).
(11) Install the right a-pillar trim panel. (Refer to
23 - BODY/INTERIOR/A-PILLAR TRIM - INSTAL-
LATION)
(12) Position the right end cap and seat the
attachment clips fully.
(13) Install the one HVAC mounting screw.
(14) Connect the radio antenna.
(15) Connect the two electrical connectors at the
right cowl panel.
(16) Install the right cowl trim cover. (Refer to 23 -
BODY/INTERIOR/COWL TRIM - INSTALLATION)
(17) Connect the air bag control module electrical
connector.
(18) Install the center bracket bolts and tighten to
12 N´m (9 ft. lbs.).
(19) Install the floor console, if equipped. (Refer to
23 - BODY/INTERIOR/FLOOR CONSOLE - INSTAL-
LATION)
(20) Install the air bag control module cover, if
equipped.
(21) Connect the park brake release handle actua-
tor rod.
(22) Install the hood release handle and tighten
the screws.
(23) Install the two bolts at the column support
bracket and tighten to 14 N´m (10 ft. lbs.).
(24) Install the steering column. (Refer to 19 -
STEERING/COLUMN - INSTALLATION)
(25) Connect the wire harness electrical connectors
above the brake pedal.
(26) Install the two top instrument panel bolts and
tighten to 12 N´m (9 ft. lbs.).
(27) Install the four top instrument panel screws.
(28) Install the instrument panel top cover. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - INSTALLATION)
INSTRUMENT PANEL
HEADLAMP SWITCH BEZEL
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) Using a trim stick C-4755 or equivalent,
release the top clips on the steering column opening
cover and the lower drivers side bezel.
(2) Using a trim stick C-4755 or equivalent,
release the switch bezel. (Fig. 17)
(3) Disconnect the electrical connector and remove
the bezel.
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) Connect the electrical connector.
Fig. 17 HEADLIGHT SWITCH BEZEL
1 - SWITCH BEZEL
2 - INSTRUMENT PANEL
3 - ELECTRICAL CONNECTOR
4 - HEADLIGHT SWITCH
23 - 56 INSTRUMENT PANELDR
INSTRUMENT PANEL ASSEMBLY (Continued)

(2) Position the switch bezel and seat the attach-
ment clips fully.
(3) Seat the clips on the steering column opening
cover and the lower drivers side bezel fully.
INSTRUMENT PANEL CENTER
BEZEL
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.
CAUTION: When removing and installing the center
bezel, use tape or other suitable material to protect
the cupholder and ash receiver from damage.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the steering column opening cover.
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - REMOVAL)
(3) Open the ashtray and cup holder.
(4) Remove the one center bezel retaining screw
(Fig. 18).
CAUTION: Extreme care must be taken not to
scratch the ashtray door while removing the instru-
ment panel center bezel. Apply masking tape to the
ashtray door if the center bezel is not being com-
pletely removed from the instrument panel.
(5) Using a trim stick C-4755 or equivalent, gently
pry the center bezel free from the instrument panel.
(6) Working behind the center bezel, disconnect all
electrical connectors and remove the bezel.
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.
CAUTION: When removing and installing the center
bezel, use tape or other suitable material to protect
the cupholder and ash receiver from damage.
(1) Working behind the center bezel, connect all
electrical connectors.
(2) Gently install the center bezel on the instru-
ment panel by pushing straight in and seat the
attachment clips fully.
(3) Install the one center bezel screw.
(4) Install the steering column opening cover.
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - INSTALLA-
TION)
(5) Connect the negative battery cable.
Fig. 18 CENTER BEZEL
1 - INSTRUMENT PANEL
2 - CENTER BEZEL
3 - SCREW
DRINSTRUMENT PANEL 23 - 57
INSTRUMENT PANEL HEADLAMP SWITCH BEZEL (Continued)

INSTRUMENT PANEL DRIVER
SIDE BEZEL
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) Using a trim stick C-4755 or equivalent, at
notch in the bottom, remove the drivers side endcap.
(2) Remove the drivers side cowl trim panel. (Refer
to 23 - BODY/INTERIOR/COWL TRIM - REMOVAL)
(3) Remove the two screws. (Fig. 19)
(4) Using a trim stick C-4755 or equivalent,
release the top clips and tilt the bezel down.
(5) Disconnect the adjustable pedal switch electri-
cal connector, if equipped.
(6) Lower the bezel down fully and remove from
the lower hooks.
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 bezel onto the lower hooks and lift
up.
(2) Connect the adjustable pedal switch electrical
connector, if equipped.
(3) Seat the upper attachment clips fully.
(4) Install the two screws.
(5) Position the endcap and seat fully.
(6) Install the drivers side cowl trim panel. (Refer
to 23 - BODY/INTERIOR/COWL TRIM - INSTALLA-
TION)
INSTRUMENT PANEL TOP
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) Using a trim stick C-4755 or equivalent, pry up
on the rear of the top cover and release the attach-
ment clips.
(2) Pull the top cover backwards to release the
remaining clips and remove the cover.
Fig. 19 LOWER DRIVERS SIDE BEZEL
1 - SCREWS (2)
2 - ADJUSTABLE PEDAL SWITCH (if equipped)
3 - PEDAL SWITCH ELECTRICAL CONNECTOR
4 - BEZEL
23 - 58 INSTRUMENT PANELDR

CONTROLS
TABLE OF CONTENTS
page page
A/C COMPRESSOR CLUTCH/COIL
DESCRIPTION..........................9
OPERATION............................9
DIAGNOSIS AND TESTING - A/C
COMPRESSOR CLUTCH COIL...........10
STANDARD PROCEDURE - A/C
COMPRESSOR CLUTCH BREAK-IN.......10
REMOVAL.............................10
INSPECTION..........................11
INSTALLATION.........................12
A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL.............................14
INSTALLATION.........................14
A/C HEATER CONTROL
DESCRIPTION.........................14
REMOVAL.............................15
INSTALLATION.........................15
A/C PRESSURE TRANSDUCER
DESCRIPTION.........................15
OPERATION...........................16
DIAGNOSIS AND TESTING - A/C PRESSURE
TRANSDUCER.......................16
REMOVAL.............................16
INSTALLATION.........................16
BLEND DOOR ACTUATOR
DESCRIPTION.........................17
OPERATION...........................17
REMOVAL.............................17
INSTALLATION.........................18
BLOWER MOTOR RESISTOR BLOCK
DESCRIPTION.........................18OPERATION...........................18
DIAGNOSIS AND TESTING - BLOWER
MOTOR RESISTOR BLOCK..............19
REMOVAL.............................19
INSTALLATION.........................19
BLOWER MOTOR SWITCH
DESCRIPTION.........................20
OPERATION...........................20
DIAGNOSIS AND TESTING - BLOWER
MOTOR SWITCH......................20
DEFROST DOOR ACTUATOR
DESCRIPTION.........................20
OPERATION...........................21
REMOVAL.............................21
INSTALLATION.........................21
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................22
INSTALLATION.........................22
MODE DOOR ACTUATOR
DESCRIPTION.........................23
OPERATION...........................23
REMOVAL.............................23
INSTALLATION.........................23
RECIRCULATION DOOR ACTUATOR
DESCRIPTION.........................24
OPERATION...........................24
REMOVAL.............................24
INSTALLATION.........................25
A/C COMPRESSOR CLUTCH/
COIL
DESCRIPTION
The compressor clutch assembly consists of a sta-
tionary electromagnetic coil, a pulley bearing and
pulley assembly, and a clutch plate (Fig. 1). The elec-
tromagnetic coil and the pulley bearing and pulley
assembly are each retained on the nose of the com-
pressor front housing with snap rings. The clutch
plate is keyed to the compressor shaft and secured
with a nut. These components provide the means toengage and disengage the compressor from the
engine serpentine accessory drive belt.
OPERATION
The A/C compressor clutch provides the means to
engage and disengage the A/C compressor from the
engine serpentine accessory drive belt. When the
clutch coil is energized, it magnetically draws the
clutch into contact with the pulley and drives the
compressor shaft. When the coil is not energized, the
pulley freewheels on the pulley bearing, which is
part of the pulley assembly. The compressor clutch
DRCONTROLS 24 - 9

and coil are the only serviced parts on the compres-
sor.
A/C compressor clutch engagement is controlled by
several components: the A/C-heater control, A/C pres-
sure transducer, A/C compressor clutch relay, evapo-
rator temperature sensor and the powertrain control
module (PCM). The PCM may delay compressor
clutch engagement for up to thirty seconds (Refer to
8 - ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/POWERTRAIN CONTROL MODULE -
DESCRIPTION).
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 controls 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 thecompressor 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 distri-
bution center (PDC)
²A/C-heater control
²A/C compressor clutch relay
²A/C pressure transducer
²Evaporator temperature sensor
²Powertrain control module (PCM)
(4) The compressor clutch coil is acceptable if the
current draw measured at the clutch coil is within
specifications with the electrical system voltage at
11.5 to 12.5 volts (Refer to 24 - HEATING & AIR
CONDITIONING - SPECIFICATIONS). 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 turning on electrical
accessories until the system voltage drops below 12.5
volts.
(a) If the clutch coil current reading is above
specifications, 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) Disconnect the compressor clutch coil wire har-
ness 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.
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/COIL (Continued)

when a minimum discharge pressure of 2756 kPa
(400 psi) is reached.
The high pressure relief valve vents only enough
refrigerant to reduce the system pressure, and then
re-seats itself. The majority of the refrigerant is con-
served in the system. If the valve vents refrigerant, it
does not mean that the valve is faulty.
The high pressure relief valve is a factory-cali-
brated unit. The valve cannot be adjusted or
repaired, and must not be removed or otherwise dis-
turbed. The valve is only serviced as a part of the
compressor assembly.
DIAGNOSIS AND TESTING - A/C COMPRESSOR
When investigating an air conditioning related
noise, you must first know the conditions under
which the noise occurs. These conditions include:
weather, vehicle speed, transmission in gear or neu-
tral, engine speed, engine temperature, and any
other special conditions. Noises that develop during
air conditioning operation 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 compressor clutch
assembly.
Drive belts are speed sensitive. At different engine
speeds and depending upon belt tension, belts can
develop noises that are mistaken for a compressor
noise. Improper belt tension can cause a misleading
noise when the compressor clutch is engaged, which
may not occur when the compressor clutch is disen-
gaged. Check the serpentine drive belt condition and
tension as described in Cooling before beginning this
procedure.
(1) Select a quiet area for testing. Duplicate the
complaint conditions as much as possible. Switch the
compressor on and off several times to clearly iden-
tify the compressor noise. Listen to the compressor
while the clutch is engaged and disengaged. Probe
the compressor with an engine stethoscope or a long
screwdriver with the handle held to your ear to bet-
ter localize the source of the noise.
(2) Loosen all of the compressor mounting hard-
ware and retighten. Tighten the compressor clutch
mounting nut. Be certain that the clutch coil is
mounted securely to the compressor, and that the
clutch plate and rotor are properly aligned and have
the correct air gap (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/A/C COMPRESSOR
CLUTCH - INSTALLATION).
(3) To duplicate a high-ambient temperature condi-
tion (high head pressure), restrict the air flow
through the condenser. Install a manifold gauge set
or a DRBIIItscan tool to be certain that the dis-
charge pressure does not exceed 2760 kPa (400 psi).(4) Check the refrigerant system plumbing for
incorrect routing, rubbing or interference, which can
cause unusual noises. Also check the refrigerant lines
for kinks or sharp bends that will restrict refrigerant
flow, which can cause noises (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE).
(5) If the noise is from opening and closing of the
high pressure relief valve, recover, evacuate and
recharge the refrigerant system (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE), (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE - REFRIGERANT SYSTEM EVACU-
ATE) and (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM CHARGE). If the high
pressure relief valve still does not seat properly,
replace the compressor (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/A/C COMPRES-
SOR - REMOVAL).
(6) If the noise is from liquid slugging on the suc-
tion line, replace the accumulator (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/AC-
CUMULATOR - REMOVAL) and check the refriger-
ant oil level and the refrigerant system charge (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/REFRIGERANT OIL - STANDARD PROCE-
DURE) (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/ACCUMULATOR -
REMOVAL). If after replacing the accumulator the
slugging condition still exists then replace the com-
pressor.(Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/A/C COMPRESSOR - REMOVAL).
(7) If the liquid slugging condition continues fol-
lowing accumulator replacement, replace the com-
pressor and repeat Step 1.
REMOVAL
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) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
NOTE: The A/C compressor may be removed and
repositioned without disconnecting the refrigerant
lines or discharging the refrigerant system. Dis-
charging is not necessary if servicing the compres-
sor clutch, clutch coil, engine, engine cylinder head
or the generator.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
DRPLUMBING 24 - 49
A/C COMPRESSOR (Continued)

ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY).
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Disconnect the A/C compressor clutch coil wire
harness connector.
(5) Depending on engine usage, remove the bolt or
nuts that secure the suction and discharge line fit-
tings to the A/C compressor.
(6) Disconnect the suction and discharge line fit-
tings from the A/C compressor.
(7) Remove the O-ring seals from the suction and
discharge line fittings and discard.
(8) Install plugs in, or tape over all of the opened
refrigerant line fittings and the compressor ports.
(9) If equipped with the 5.7L Hemi engine, remove
the nuts and bolts that secure the generator and A/C
compressor support bracket and remove the bracket
from the engine.
(10) Remove the bolts that secure the A/C com-
pressor to the mounting bracket (Fig. 4), (Fig. 5) or
(Fig. 6).
(11) Remove the A/C compressor from the engine
compartment.
Fig. 4 A/C Compressor - 3.7L Shown, 4.7L Typical
1 - BOLT #1
2 - BOLT #2
3 - BOLT #3
4 - A/C COMPRESSOR
5 - A/C CLUTCH AND PULLEY
6 - MOUNTING BRACKET
Fig. 5 A/C Compressor - 5.7L Hemi
1 - BOLT (2)
2 - A/C COMPRESSOR
3 - BOLT
4 - MOUNTING BRACKET
Fig. 6 A/C Compressor - 5.9L Diesel
1 - ENGINE BLOCK
2 - MOUNTING BRACKET
3 - A/C COMPRESSOR
4 - BOLT (4)
24 - 50 PLUMBINGDR
A/C COMPRESSOR (Continued)

(11) Install the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(12) Reconnect the battery negative cable.
(13) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
(14) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
A/C CONDENSER
DESCRIPTION
The condenser is located in the air flow next to the
engine cooling radiator. The condenser is a heat
exchanger that allows the high-pressure refrigerant
gas being discharged by the compressor to give up its
heat to the air passing over the condenser fins.
OPERATION
When air passes through the condenser fins, the
high-pressure refrigerant gas within the A/C con-
denser gives up its heat. The refrigerant then con-
denses as it leaves the A/C condenser and becomes a
high-pressure liquid. The volume of air flowing over
the condenser fins is critical to the proper cooling
performance of the air conditioning system. There-fore, it is important that there are no objects placed
in front of the radiator grille openings at the front of
the vehicle or foreign material on the condenser fins
that might obstruct proper air flow. Also, any factory-
installed air seals or shrouds must be properly rein-
stalled following radiator or A/C condenser service.
The A/C condenser cannot be repaired and, if
faulty or damaged, it must be replaced.
REMOVAL
REMOVAL - 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) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY).
(3) Remove the nut that secures the discharge line
fitting to the condenser inlet port (Fig. 10).
(4) Disconnect the discharge line from the con-
denser.
(5) Remove the seal from the discharge line fitting
and discard.
(6) Install plugs in, or tape over the discharge line
fitting and condenser inlet port.
(7) Remove the plastic cover from the condenser
outlet stud.
(8) Remove the nut that secures the liquid line fit-
ting to the condenser outlet.
(9) Disconnect the liquid line from the condenser.
(10) Remove the seal from the liquid line fitting
and discard.
(11) Install plugs in, or tape over the liquid line
fitting and condenser outlet port.
(12) Disconnect the wire harness connector from
the condenser cooling fan motor (Fig. 11).
(13) Remove the two bolts that secure the con-
denser to the front upper crossmember.
(14) Remove the condenser/cooling fan assembly
from the vehicle.
(15) Place the condenser/cooling fan assembly on a
flat work area and remove the four screws that
secure the cooling fan to the condenser.
(16) Separate the cooling fan from the condenser.
Fig. 9 A/C Compressor - 5.9L Diesel
1 - ENGINE BLOCK
2 - MOUNTING BRACKET
3 - A/C COMPRESSOR
4 - BOLT (4)
24 - 52 PLUMBINGDR
A/C COMPRESSOR (Continued)