1998 DODGE RAM 1500 cooling

PLUMBING
TABLE OF CONTENTS
page page
PLUMBING
DESCRIPTION - REFRIGERANT LINE.......42
OPERATION- REFRIGERANT LINES........42
WARNING
ENGINE COOLING SYSTEM.............42
A/C SYSTEM.........................43
CAUTION
A/C SYSTEM.........................43
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS......................44
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
TUBING AND FITTINGS.................45
STANDARD PROCEDURE - DIODE
REPLACEMENT.......................45
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT..........46
STANDARD PROCEDURE - REFRIGERANT
RECOVERY..........................47
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE...................47
STANDARD PROCEDURE - REFRIGERANT
SYSTEM CHARGE.....................47
A/C COMPRESSOR
DESCRIPTION
DESCRIPTION - A/C COMPRESSOR.......48
DESCRIPTION - HIGH PRESSURE RELIEF
VALVE..............................48
OPERATION
OPERATION - A/C COMPRESSOR........48
OPERATION - HIGH PRESSURE RELIEF
VALVE..............................48
DIAGNOSIS AND TESTING - A/C
COMPRESSOR.......................49
REMOVAL.............................49
INSTALLATION.........................51
A/C CONDENSER
DESCRIPTION.........................52
OPERATION...........................52
REMOVAL
REMOVAL - 3.7, 4.7 AND 5.7L ENGINES....52
REMOVAL - 5.9L DIESEL ENGINE.........53
INSTALLATION
INSTALLATION - 3.7, 4.7 AND 5.7L ENGINES . 53
INSTALLATION - 5.9L DIESEL ENGINE.....54
A/C CONDENSER FAN
REMOVAL - 3.7, 4.7 and 5.7L ENGINES......55
INSTALLATION - 3.7, 4.7 and 5.7L ENGINES . . . 55A/C DISCHARGE LINE
DESCRIPTION.........................56
REMOVAL
REMOVAL - 5.9L DIESEL ENGINE.........56
REMOVAL - 3.7L/4.7L AND 5.7L HEMI
ENGINE.............................57
INSTALLATION
INSTALLATION - 5.9L DIESEL ENGINE.....58
INSTALLATION - 3.7L/4.7L AND 5.7L HEMI
ENGINE.............................59
A/C EVAPORATOR
DESCRIPTION.........................59
OPERATION...........................59
REMOVAL.............................60
INSTALLATION.........................60
A/C ORIFICE TUBE
DESCRIPTION.........................60
OPERATION...........................60
DIAGNOSIS AND TESTING - A/C ORIFICE
TUBE...............................61
ACCUMULATOR
DESCRIPTION.........................61
OPERATION...........................61
REMOVAL.............................61
INSTALLATION.........................62
HEATER CORE
DESCRIPTION.........................63
OPERATION...........................63
REMOVAL.............................63
INSTALLATION.........................63
HEATER INLET HOSE
REMOVAL.............................64
INSTALLATION.........................64
HEATER RETURN HOSE
REMOVAL.............................64
INSTALLATION.........................65
LIQUID LINE
DESCRIPTION.........................65
REMOVAL.............................65
INSTALLATION.........................66
REFRIGERANT
DESCRIPTION.........................67
OPERATION...........................67
REFRIGERANT LINE COUPLER
DESCRIPTION.........................67
OPERATION...........................67
REMOVAL.............................68
INSTALLATION.........................68
DRPLUMBING 24 - 41

REFRIGERANT OIL
DESCRIPTION.........................68
OPERATION...........................69
STANDARD PROCEDURE - REFRIGERANT
OIL LEVEL...........................69
SERVICE PORT VALVE CORE
DESCRIPTION.........................70
REMOVAL - SERVICE PORT VALVE CORES . . 70
INSTALLATION.........................70
SUCTION LINE
DESCRIPTION.........................70REMOVAL
REMOVAL - 5.9L DIESEL ENGINE.........70
REMOVAL - 3.7L/4.7L AND 5.7L HEMI
ENGINE.............................71
INSTALLATION
INSTALLATION - 5.9L DIESEL ENGINE.....72
INSTALLATION - 3.7L/4.7L AND 5.7L HEMI
ENGINE.............................73
PLUMBING
DESCRIPTION - REFRIGERANT LINE
The refrigerant lines and hoses are used to carry
the refrigerant between the various air conditioning
system components. A barrier hose design with a
nylon tube, which is sandwiched between rubber lay-
ers, is used for the R-134a air conditioning system on
this vehicle. This nylon tube helps to further contain
the R-134a refrigerant, which has a smaller molecu-
lar structure than R-12 refrigerant. The ends of the
refrigerant hoses are made from lightweight alumi-
num or steel, and commonly use braze-less fittings.
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. 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.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from an exhaust manifold.
OPERATION- REFRIGERANT LINES
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
The refrigerant lines and hoses are coupled with
other components of the HVAC system with either
O-rings or dual plane seals.
The refrigerant lines and hoses cannot be repaired
and, if faulty or damaged, they must be replaced.
WARNING
ENGINE COOLING SYSTEM
WARNING: THE ENGINE COOLING SYSTEM IS
DESIGNED TO DEVELOP INTERNAL PRESSURES
OF 97 TO 123 KILOPASCALS (14 TO 18 POUNDS
PER SQUARE INCH). DO NOT REMOVE OR
LOOSEN THE COOLANT PRESSURE CAP, CYLIN-
DER BLOCK DRAIN PLUGS, RADIATOR DRAIN,
RADIATOR HOSES, HEATER HOSES, OR HOSE
CLAMPS WHILE THE ENGINE COOLING SYSTEM IS
HOT AND UNDER PRESSURE. FAILURE TO
OBSERVE THIS WARNING CAN RESULT IN SERI-
OUS BURNS FROM THE HEATED ENGINE COOL-
ANT. ALLOW THE VEHICLE TO COOL FOR A
MINIMUM OF 15 MINUTES BEFORE OPENING THE
COOLING SYSTEM FOR SERVICE.
24 - 42 PLUMBINGDR

DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS
WARNING: R-134a SERVICE EQUIPMENT OR VEHI-
CLE A/C SYSTEM SHOULD NOT BE PRESSURE
TESTED OR LEAK TESTED WITH COMPRESSED
AIR. MIXTURE OF AIR and R-134a CAN BE COM-
BUSTIBLE AT ELEVATED PRESSURES. THESE MIX-
TURES ARE POTENTIALLY DANGEROUS AND MAY
RESULT IN FIRE OR EXPLOSION CAUSING INJURY
OR PROPERTY DAMAGE.
AVOID BREATHING A/C REFRIGERANT AND LUBRI-
CANT VAPOR OR MIST. EXPOSURE MAY IRRITATE
EYES, NOSE AND THROAT. USE ONLY APPROVED
SERVICE EQUIPMENT MEETING SAE REQUIRE-
MENTS TO DISCHARGE R-134a SYSTEM. IF ACCI-
DENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE WORK AREA BEFORE RESUMING SER-
VICE.
NOTE: The refrigerant system does come from the
factory with a yellow tracer dye already installed to
aid in detection of leaks.
If the A/C system is not cooling properly, determine
if the refrigerant system is fully charged with
R-134a. This is accomplished by performing a system
Charge Level-Check or Fill. If while performing this
test A/C liquid line pressure is less than 345 kPa (50
psi) proceed to System Empty procedure. If liquid
line pressure is greater than 345 kPa (50 psi) proceed
to System Low procedure. If the refrigerant system is
empty or low in refrigerant charge, a leak at any line
fitting or component seal is likely. A review of the fit-
tings, lines and components for oily residue is an
indication of the leak location. To detect a leak in the
refrigerant system, perform one of the following pro-
cedures as indicated by the symptoms.
SYSTEM EMPTY
(1) Evacuate the refrigerant system to the lowest
degree of vacuum possible (approx. 28 in Hg.). Deter-
mine if the system holds a vacuum for 15 minutes. If
vacuum is held, a leak is probably not present. If sys-
tem will not maintain vacuum level, proceed with
this procedure.(2) Prepare a 0.284 Kg. (10 oz.) refrigerant charge
to be injected into the system.
(3) Connect and dispense 0.284 Kg. (10 oz.) of
refrigerant into the evacuated refrigerant system.
(4) Proceed to Step 2 of System Low procedure.
SYSTEM LOW
(1) Determine if there is any (R-134a) refrigerant
in the system.
(2) Position the vehicle in a wind free work area.
This will aid in detecting small leaks.
(3) Bring the refrigerant system up to operating
temperature and pressure. This is done by allowing
the engine to run for five minutes with the system
set to the following:
²Transmission in Park or Neutral with parking
brake set
²Engine idling at 700 rpm
²A/C controls set in 100 percent outside air
²Blower switch in the high A/C position
²A/C in the ON position
²Open all windows
CAUTION: A leak detector designed for R-12 refrig-
erant (only) will not detect leaks in a R-134a refrig-
erant system.
(4) Shut off the vehicle and wait 2 to 7 minutes.
Then use an Electronic Leak Detector that is
designed to detect R-134a type refrigerant and search
for leaks. Fittings, lines, or components that appear
to be oily usually indicates a refrigerant leak. To
inspect the evaporator core for leaks, insert the leak
detector probe into the drain tube opening or a heat
duct. A R-134a dye is available to aid in leak detec-
tion, use only DaimlerChrysler approved refrigerant
dye.
24 - 44 PLUMBINGDR
PLUMBING (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)

REMOVAL - 5.9L DIESEL ENGINE
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 plastic cover from the condenser
inlet stud.
(4) Remove the nut that secures the discharge line
fitting to the condenser inlet port (Fig. 12).
(5) Disconnect the discharge line from the con-
denser.
(6) Remove the seal from the discharge line fitting
and discard.
(7) Install plugs in, or tape over the discharge line
fitting and condenser inlet port.
(8) Remove the plastic cover from the condenser
outlet stud.
(9) Remove the nut that secures the liquid line fit-
ting to the condenser outlet.
(10) Disconnect the liquid line from the condenser.
(11) Remove the seal from the liquid line fitting
and discard.
(12) Install plugs in, or tape over the liquid line
fitting and condenser inlet port.
(13) Remove the four bolts that secure the con-
denser to the charge air cooler.
(14) Remove the condenser from the engine com-
partment.
INSTALLATION
INSTALLATION - 3.7, 4.7 AND 5.7L ENGINES
NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
(1) Position the condenser cooling fan onto the A/C
condenser.
(2) Install and tighten the four screws that secure
the condenser cooling fan to the A/C condenser.
Tighten the screws to 2.2 N´m (20 in. lbs.).
(3) Carefully position the condenser/cooling fan
assembly into the engine compartment.
Fig. 10 A/C Discharge Line - 3.7L Shown, 4.7L/5.7L
Typical
1 - NUT
2 - FRONT UPPER CROSSMEMBER
3 - A/C CONDENSER
4 - NUT (2)
5 - SUCTION LINE
6 - A/C COMPRESSOR
7 - A/C PRESSURE TRANSDUCER
8 - WIRE HARNESS CONNECTOR
9 - A/C DISCHARGE LINE
Fig. 11 Condenser/Cooling Fan Assembly
1 - LH MOUNTING BOLT
2 - FRONT UPPER CROSSMEMBER
3 - LOWER MOUNTING FLANGE
4 - UPPER MOUNTING SCREW (2)
5 - LOWER MOUNTING SCREW (2)
6 - MOUNTING TABS
7 - CONDENSER COOLING FAN MOTOR
8 - COOLING FAN WIRE CONNECTOR
9 - RH MOUNTING BOLT
DRPLUMBING 24 - 53
A/C CONDENSER (Continued)

(4) Align the condenser lower mounting tabs to the
mounting flanges.
(5) Install the two bolts that secure the condenser/
cooling fan assembly to the upper front crossmember.
Tighten the bolts to 10.5 N´m (95 in. lbs.).
(6) Connect the wire harness connector to the con-
denser cooling fan motor.
(7) Remove the tape or plugs from the liquid line
fitting and condenser outlet port.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
Use only the specified O-ring as it is made of a spe-
cial material for the R-134a system. Use only refrig-
erant oil of the type recommended for the A/C
compressor in the vehicle.
(9) Connect the liquid line to the condenser outlet
port.
(10) Install and tighten the nut that secures the
liquid line fitting to the condenser. Tighten the nut to
20 N´m (180 in. lbs.).
(11) Install the plastic cover onto the condenser
outlet stud.
(12) Remove the tape or plugs from the discharge
line fitting and condenser inlet port.(13) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting. Use only the specified O-ring as it is made of a
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
(14) Connect the discharge line to the condenser
inlet port.
(15) Install and tighten the nut that secures the
discharge line fitting to the condenser. Tighten the
nut to 20 N´m (180 in. lbs.).
(16) Reconnect the battery negative cable.
(17) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(18) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
INSTALLATION - 5.9L DIESEL ENGINE
NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
(1) Position the condenser into the engine compart-
ment.
(2) Install the four bolts that secure the condenser
to the charge air cooler. Tighten the bolts to 10.5 N´m
(95 in. lbs.).
(3) Remove the tape or plugs from the liquid line
fitting and condenser outlet port.
(4) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
Use only the specified O-ring as it is made of a spe-
cial material for the R-134a system. Use only refrig-
erant oil of the type recommended for the A/C
compressor in the vehicle.
(5) Connect the liquid line to the condenser outlet
port.
(6) Install and tighten the nut that secures the liq-
uid line fitting to the condenser. Tighten the nut to
20 N´m (180 in. lbs.).
(7) Install the plastic cover onto the condenser out-
let stud.
(8) Remove the tape or plugs from the discharge
line fitting and condenser inlet port.
(9) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting. Use only the specified O-ring as it is made of a
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
Fig. 12 Condenser - 5.9L Diesel Engine
1 - DISCHARGE LINE
2 - MOUNTING BOLT
3 - LIQUID LINE
4 - MOUNTING BOLT
5 - A/C CONDENSER
6 - MOUNTING BOLT
7 - MOUNTING BOLT
24 - 54 PLUMBINGDR
A/C CONDENSER (Continued)