1998 DODGE RAM 1500 system

(3) Install the instrument panel top cover (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - INSTALLATION).
(4) Install the left side panel duct adapter.
(5) Install the left side intermediate demister duct.
(6) Install the right side intermediate demister
duct.
(7) Install the right side panel duct adapter.
(8) Install the center distribution duct to the
instrument panel support.
(9) Install the two screws that secure the center
distribution duct to the instrument panel support.
Tighten the screws to 2.2 N´m (20 in. lbs.).
(10) Install the defroster ducts (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
DEFROSTER DUCTS - INSTALLATION).
MODE DOOR
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the instrument panel from the vehicle
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(2) Remove the mode door actuator and sleeve
from the upper half of the HVAC housing (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS/
MODE DOOR ACTUATOR - REMOVAL).
(3) Remove the two screws that secure the mode
door adapter to the top the HVAC housing (Fig. 13).
(4) Disconnect the two plastic retainer clips that
secure the mode door adapter to the front the HVAC
housing and remove the mode door adapter.
(5) Remove the screws that secure the two mode
door spring retainers to the top the HVAC housing
and remove the retainers.
(6) Remove the mode door cover from the top the
HVAC housing.
(7) Gently slide the mode door toward the outside
of the housing. Tilt and lift the door out of the hous-
ing.
(8) Inspect the mode door, seals and the HVAC
housing for damage or binding and repair or replace
components as required.
INSTALLATION
(1) Position the mode door pivot shaft into the
pivot hole in the upper half of the HVAC housing.
(2) Install the mode door by carefully tipping the
door into the HVAC housing, then sliding the door
into it's operating position.
(3) Install the mode door cover onto the top the
HVAC housing.
(4) Install the screws that secure the mode door
spring retainers to the top the HVAC housing.
Tighten the screws to 2.2 N´m (20 in. lbs.).
(5) Install the mode door adapter to the top the
HVAC housing. Connect the two plastic retainer clips
Fig. 12 Instrument Panel Ducts
1 - RIGHT SIDE PANEL DUCT
2 - RIGHT SIDE PANEL DUCT ADAPTER
3 - RIGHT SIDE INTERMEDIATE DEMISTER DUCT
4 - LEFT SIDE INTERMEDIATE DEMISTER DUCT
5 - LEFT SIDE PANEL DUCT
6 - LEFT SIDE PANEL DUCT ADAPTER
24 - 38 DISTRIBUTIONDR
INSTRUMENT PANEL DUCTS (Continued)

that secure the mode door adapter to the front the
HVAC housing.
(6) Install the two screws that secure the mode
door adapter to the top of the HVAC housing.
Tighten the screws to 2.2 N´m (20 in. lbs.).
(7) Install the mode door actuator and sleeve to
the upper half of the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS/
MODE DOOR ACTUATOR - INSTALLATION).
(8) Install the instrument panel (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION).
RECIRCULATION DOOR
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the HVAC housing from the vehicle
and place it on the workbench (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - REMOVAL).
(2) Remove the recirculation door actuator from
the recirculation housing (Refer to 24 - HEATING &
AIR CONDITIONING/CONTROLS/RECIRCULA-
TION DOOR ACTUATOR - REMOVAL).
(3) Remove the two screws and disengage the two
plastic retaining tabs that secure the recirculation
housing to the HVAC housing (Fig. 14).
(4) Remove the recirculation housing from the
HVAC housing.
(5) Gently slide the recirculation door toward the
outside of the recirculation housing. Tilt and lift the
door out of the housing.
(6) Inspect the recirculation door, seals and the
HVAC recirculation housing for damage or binding
and repair or replace components as required.
Fig. 13 HVAC Mode Door
1 - MODE DOOR ADAPTER
2 - SPRING RETAINER
3 - SCREW (2)
4 - MODE DOOR ACTUATOR
5 - MODE DOOR
DRDISTRIBUTION 24 - 39
MODE DOOR (Continued)

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

A/C SYSTEM
WARNING: THE AIR CONDITIONING SYSTEM CON-
TAINS REFRIGERANT UNDER HIGH PRESSURE.
SEVERE PERSONAL INJURY MAY RESULT FROM
IMPROPER SERVICE PROCEDURES. REPAIRS
SHOULD ONLY BE PERFORMED BY QUALIFIED
SERVICE PERSONNEL.
AVOID BREATHING THE REFRIGERANT AND
REFRIGERANT OIL VAPOR OR MIST. EXPOSURE
MAY IRRITATE THE EYES, NOSE, AND/OR THROAT.
WEAR EYE PROTECTION WHEN SERVICING THE
AIR CONDITIONING REFRIGERANT SYSTEM. SERI-
OUS EYE INJURY CAN RESULT FROM DIRECT
CONTACT WITH THE REFRIGERANT. IF EYE CON-
TACT OCCURS, SEEK MEDICAL ATTENTION IMME-
DIATELY.
DO NOT EXPOSE THE REFRIGERANT TO OPEN
FLAME. POISONOUS GAS IS CREATED WHEN
REFRIGERANT IS BURNED. AN ELECTRONIC LEAK
DETECTOR IS RECOMMENDED.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE THE WORK AREA BEFORE RESUMING
SERVICE. LARGE AMOUNTS OF REFRIGERANT
RELEASED IN A CLOSED WORK AREA WILL DIS-
PLACE THE OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF R-134a REFRIGER-
ANT AT AVERAGE TEMPERATURE AND ALTITUDE
IS EXTREMELY HIGH. AS A RESULT, ANYTHING
THAT COMES IN CONTACT WITH THE REFRIGER-
ANT WILL FREEZE. ALWAYS PROTECT THE SKIN
OR DELICATE OBJECTS FROM DIRECT CONTACT
WITH THE REFRIGERANT.
THE R-134a SERVICE EQUIPMENT OR THE VEHI-
CLE REFRIGERANT SYSTEM SHOULD NOT BE
PRESSURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR. SOME MIXTURES OF AIR AND
R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE
AT ELEVATED PRESSURES. THESE MIXTURES ARE
POTENTIALLY DANGEROUS, AND MAY RESULT IN
FIRE OR EXPLOSION CAUSING INJURY OR PROP-
ERTY DAMAGE.
CAUTION
A/C SYSTEM
CAUTION: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions supplied
with the service equipment being used.
Never add R-12 to a refrigerant system designed to
use R-134a and do not use R-12 equipment or parts
on the R-134a system. Damage to the system will
result.
R-12 refrigerant oil must not be mixed with R-134arefrigerant oil. They are not compatible and damage
to the system will result.
Do not overcharge the refrigerant system. Over-
charging will cause excessive compressor head
pressure and can cause noise and system failure.
Recover the refrigerant before opening any fitting
or connection. Open the fittings with caution, even
after the system has been discharged. Never open
or loosen a connection before recovering the refrig-
erant.
If equipped, do not remove the secondary retention
clip from any spring-lock coupler connection while
the refrigerant system is under pressure. Recover
the refrigerant before removing the secondary
retention clip. Open the fittings with caution, even
after the system has been discharged. Never open
or loosen a connection before recovering the refrig-
erant.
Do not open the refrigerant system or uncap a
replacement component until you are ready to ser-
vice the system. This will prevent contamination in
the system. Before disconnecting a component,
clean the outside of the fittings thoroughly to pre-
vent contamination from entering the refrigerant
system. Immediately after disconnecting a compo-
nent from the refrigerant system, seal the open fit-
tings with a cap or plug.
Refrigerant oil will absorb moisture from the atmo-
sphere if left uncapped. Do not open a container of
refrigerant oil until you are ready to use it. Replace
the cap on the oil container immediately after using.
Store refrigerant oil only in a clean, airtight, and
moisture-free container.
Keep service tools and the work area clean. Con-
tamination of the refrigerant system must be
avoided.
CAUTION: The use of A/C system sealers may
result in damage to A/C refrigerant recovery/evacu-
ation/recharging equipment and/or A/C systems.
Many federal, state/provincial and local regulations
prohibit the recharge of A/C systems with known
leaks. DaimlerChrysler recommends the detection
of A/C system leaks through the use of approved
leak detectors and fluorescent leak detection dyes.
Vehicles found with A/C system sealers should be
treated as contaminated and replacement of the
entire A/C refrigerant system is recommended. A/C
systems found to be contaminated with A/C system
sealers, A/C stop-leak products or seal conditioners
voids the warranty for the A/C system.
DRPLUMBING 24 - 43
PLUMBING (Continued)

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)

STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING TUBING
AND FITTINGS
CAUTION: The system must be completely empty
before opening any fitting or connection in the
refrigeration system. Open fittings with caution
even after the system has been emptied. If any
pressure is noticed as a fitting is loosened,
retighten fitting and evacuate the system again.
A good rule for the flexible hose lines is to keep the
radius of all bends at least 10 times the diameter of
the hose. Sharper bends will reduce the flow of
refrigerant. The flexible hose lines should be routed
so they are at least 3 inches (80 mm) from the
exhaust manifold. Inspect all flexible hose lines to
make sure they are in good condition and properly
routed.
The use of correct wrenches when making connec-
tions is very important. Improper wrenches or
improper use of wrenches can damage the fittings.
The internal parts of the A/C system will remain sta-
ble as long as moisture-free refrigerant and refrig-
erant oil is used. Abnormal amounts of dirt,
moisture or air can upset the chemical stability.
This may cause operational troubles or even seri-
ous damage if present in more than very small
quantities. Before disconnecting a component,
clean the outside of the fittings thoroughly to pre-
vent contamination from entering the refrigerant
system.
When opening a refrigeration system, have every-
thing you will need to repair the system ready. This
will minimize the amount of time the system must
be opened. Cap or plug all lines and fittings as
soon as they are opened. This will help prevent the
entrance of dirt and moisture. All new lines and
components should be capped or sealed until they
are ready to be used. Before connecting a compo-
nent, clean the outside of the fittings thoroughly to
prevent contamination from entering the refrigerant
system.
All tools, including the refrigerant dispensing mani-
fold, the manifold gauge set, and test hoses should
be kept clean and dry.
Kinks in the refrigerant tubing or sharp bends in
the refrigerant hose lines will greatly reduce the
capacity of the entire system. High pressures are pro-
duced in the system when it is operating. Extreme
care must be exercised to make sure that all connec-
tions are pressure tight. Dirt and moisture can enter
the system when it is opened for repair or replace-
ment of lines or components. The refrigerant oil willabsorb moisture readily out of the air. This moisture
will convert into acids within a closed system.
STANDARD PROCEDURE - DIODE
REPLACEMENT
(1) Disconnect and isolate the battery negative
cable. If the vehicle has dual batteries, remove the
negative cable from both batteries.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness. Note the
direction of current flow (Fig. 1).
(4) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(5) Install the new diode in the harness, making
sure current flow is correct. If necessary refer to the
appropriate wiring diagram for current flow.
(6) Solder the connections together using rosin
core type solder only.Do not use acid core solder.
(7) Tape the diode to the harness using electrical
tape. Make sure the diode is completely sealed from
the elements.
(8) Reconnect the battery negative cable(s) and
test the affected systems.
Fig. 1 Diode Identification
1 - CURRENT FLOW
2 - BAND INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN WIRING DIAGRAMS
DRPLUMBING 24 - 45
PLUMBING (Continued)

STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT
WARNING: EYE PROTECTION MUST BE WORN
WHEN SERVICING AN AIR CONDITIONING REFRIG-
ERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE)
ALL VALVES ON THE EQUIPMENT BEING USED
BEFORE CONNECTING TO, OR DISCONNECTING
FROM THE REFRIGERANT SYSTEM. FAILURE TO
OBSERVE THESE WARNINGS MAY RESULT IN PER-
SONAL INJURY.
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).
When servicing the air conditioning system, a
R-134a refrigerant recovery/recycling/charging sta-
tion that meets SAE Standard J2210 must be used
(Fig. 2). Contact an automotive service equipment
supplier for refrigerant recovery/recycling/charging
equipment. Refer to the operating instructions sup-
plied by the equipment manufacturer for proper care
and use of this equipment.
A manifold gauge set may be needed with some
recovery/recycling/charging equipment (Fig. 3). The
service hoses on the gauge set being used should
have manual (turn wheel), or automatic back-flow
valves at the service port connector ends. This will
prevent refrigerant from being released into the
atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
LOW PRESSURE GAUGE HOSE The low pressure
hose (Blue with Black stripe) attaches to the low side
service port. This service port is located on the suc-
tion line between the accumulator outlet port and the
A/C compressor.
HIGH PRESSURE GAUGE HOSE The high pres-
sure hose (Red with Black stripe) attaches to the
high side service port. This service port is located on
the discharge line near the A/C compressor. On this
model, an A/C pressure transducer is installed onto
the high pressure service port. A/C high side pres-
sures can be read using a DRBIIItscan tool. Refer to
Body Diagnostic Procedures.
RECOVERY/RECYCLING/EVACUATION/CHARG-
ING HOSE The center manifold hose (Yellow, or
White, with Black stripe) is used to recover, evacu-
ate, and charge the refrigerant system. When the low
or high pressure valves on the manifold gauge set
are opened, the refrigerant in the system will escape
through this hose.
Fig. 2 Refrigerant Recovery/Recycling Station -
Typical
1 - R-134a REFRIGERANT STATION
Fig. 3 MANIFOLD GAUGE SET - TYPICAL
1 - HIGH PRESSURE GAUGE
2 - VALVE
3 - VACUUM/REFRIGERANT HOSE (YELLOW W/ BLACK STRIPE)
4 - HIGH PRESSURE HOSE (RED W/ BLACK STRIPE)
5 - LOW PRESSURE HOSE (BLUE W/ BLACK STRIPE)
6 - VALVE
7 - LOW PRESSURE GAUGE
24 - 46 PLUMBINGDR
PLUMBING (Continued)