1999 DODGE RAM charging

VALVE LOCATIONS under SYSTEM SERVICE VALVES.
2) Turn equipment on and recover refrigerant according to
equipment manufacturer's operating instructions. Allow equipment to
operate until refrigerant is recovered. Close inlet valve (if
equipped) on refrigerant recovery/recycling/charging center and turn
equipment off.
NOTE: On some applications, refrigerant recovery/recycling/charging
center will automatically shut off through the use of a low
pressure switch. On other applications, refrigerant
recovery/recycling/charging center must be manually shut
off.
3) Allow A/C system to remain closed for about 2 minutes
while observing vacuum pressure readings. If vacuum pressure reading
increases, repeat step 2) until vacuum pressure readings remain stable
for 2 minutes. If vacuum pressure readings remain stable for 2
minutes, disconnect hoses from service ports and perform required A/C
system repairs.
GENERAL MOTORS
Manufacturer recommends using A/C Refrigerant Recovery,
Recycling And Recharging (ACR4) System (J-39500). The ACR4 system ha\
s
one filtering cycle during recovery plus an automatic multiple pass
filtering during evacuation cycle. Follow manufacturer's instructions
provided with ACR4 equipment being used.
JEEP
Manufacturer recommends using refrigerant recovery/recycling
equipment which meets SAE standard J1991 or J2210. Always follow
instructions provided with the recovery/recycling equipment being
used.
FLUSHING A/C SYSTEM
There is considerable controversy over the question of
whether or not to flush A/C systems or how to go about it. Before CFCs
were classified as harmful to the environment, it was a common
practice to open flush contaminants from a system. The waste fluid was
vented to the atmosphere. This practice is now ILLEGAL and can no
longer be used.
Most OEMs don't recommend A/C system flushing. They recommend
replacing the defective component and installing a liquid line (in-
line) filter ahead of the expansion valve or orifice tube. Ford Motor
Company is one exception to this rule.
CHRYSLER CORP.
Information is not available from manufacturer.
FORD MOTOR CO.
NOTE: DO NOT flush accumulator/receiver-drier, muffler, hoses and
thermal expansion valve/fixed orifice tube as residual
flushing agent cannot be completely removed from these
components. These components are generally replaced after A/C
system contamination. Hoses can be reused, unless they are
clogged with debris. Only flush evaporator core and condenser
core, and metal inlet and outlet lines.

1) Manufacturer recommends flushing contaminated system using
one gallon of Ford A/C System Flushing Solvent (F4AZ-19579-A), a
Filter (FL-1A), an A/C Flusher Fitting Kit (014-00992). DO NOT reuse\
flushing solvent and filter, they are intended to be used on one
vehicle only.
2) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Flush specified A/C components using A/C
System Flusher (014-00991), according to manufacturer's operating
instructions.
3) If an A/C system flusher is not available to clean A/C
system, an in-line filter kit can be used. Filter kit is installed
before replacement compressor, accumulator/receiver-drier, muffler,
and thermal expansion valve/fixed orifice tube have been installed.
4) Filter kits are used with either a rubber lined suction
hose or with a nylon lined suction hose located between compressor and
evaporator. Rubber lined hose has a wall thickness of 1/4" and nylon
lined hose has a wall thickness of 1/8". See Fig. 22.
5) The filter kit for either type hose has 2 filters. A
temporary pancake filter and a permanent in-line suction filter.
Pancake filter is temporarily installed between condenser and
condenser-to-evaporator line. See Fig. 23. Permanent filter is
installed in suction line between accumulator and compressor.
6) Install replacement components (compressor, accumulator
and fixed orifice) with correct amount of refrigerant oil. See
COMPRESSOR REFRIGERANT OIL CHECKING article.
7) Cut suction hose between compressor and accumulator
(closer to compressor). Remove a length of suction hose to accommodate\
suction filter. Measure side wall of suction hose and install
appropriate filter with "O" rings and filter clamps. If side wall is
1/4", use in-line filter labeled USE WITH RUBBER INNER LINED HOSE. If
side wall is 1/8", use in-line filter labeled USE WITH NYLON INNER
LINED HOSE. Ensure arrow on filter is pointing in direction of
refrigerant flow. Tighten hose clamps to 54 INCH lbs. (6 N.m). See
Fig. 22 .
8) Install pancake filter in liquid line between condenser
and condenser-to-evaporator line. Ensure filter inlet (label) is
toward condenser. Evacuate, charge, and leak test A/C system. See
EVACUATING A/C SYSTEM, CHARGING A/C SYSTEM and LEAK TESTING. Check
filters and hoses for clearance from other engine components. Use tie
straps if necessary.
9) Place an external cooling fan in front of radiator. Select
MAX A/C operation and set blower motor speed to maximum. Start engine
and allow to idle. Ensure A/C is operating properly. Slowly increase
engine speed to 800 RPM, then 1000 RPM, and then to 1200 RPM. With
engine speed set to 1200 RPM, operate engine for one hour with A/C
system operating.
10) Stop engine. Discharge A/C system, using approved
refrigerant recovery/recycling equipment. Remove pancake filter, hoses
and fittings. Discard pancake filter. Reconnect liquid line, evacuate,
charge, and leak test A/C system. Ensure A/C system is operating
properly.

Avenger 2.5L & Sebring Coupe 2.5L
Connect approved recovery/recycling equipment to vehicle.
Evacuate A/C system using recovery/recycling equipment according to
manufacturer's instructions.
Dakota, Durango, Ram Pickup & Ram Van/Wagon
1) Connect approved recovery/recycling equipment and manifold
gauge set. Fully open manifold gauge set low-side and high-side
valves, and start vacuum pump. Operate vacuum pump until low-side
vacuum reading of 26 in. Hg or more. Close all valves and turn vacuum
pump off. Observe vacuum gauge and go to next step.
2) If A/C system maintains specified vacuum for 5 minutes,
restart vacuum pump, open low-side and high-side valves, and evacuate
system for an additional 10 minutes. Close all valves. Turn vacuum
pump off and disconnect pump.
3) If A/C system cannot get to or maintain specified vacuum,
check for a defective vacuum pump or a leak in A/C system or gauge
set. See LEAK TESTING. Repair or replace components as necessary.
All Other Models
1) Connect approved recovery/recycling equipment and manifold
gauge set to vacuum pump. Fully open manifold gauge set suction and
discharge valves, and start vacuum pump. Operate vacuum pump at least
45 minutes with a low-side vacuum reading of 26 in. Hg or more (28 in.
Hg or more on Neon). Close all valves. Turn vacuum pump off and
observe vacuum gauge.
2) If A/C system maintains specified vacuum for 30 minutes,
open all valves, start vacuum pump and operate for an additional 10
minutes. Close all valves. Turn vacuum pump off and disconnect pump.
If A/C system cannot get to or maintain specified vacuum for 30
minutes, check for a defective vacuum pump or leak in A/C system or
gauge set. See LEAK TESTING. Repair or replace A/C system components
as necessary.
FORD MOTOR CO.
1) If using approved Recovery/Recycling/Charging Center (023-\
00150) connect to high-side and low-side service valves. See SERVICE
VALVE LOCATIONS under SYSTEM SERVICE VALVES. Connect manifold gauge
set center hose to vacuum pump.
2) Open both valves on manifold gauge set. Operate vacuum
pump until low-side vacuum reading is at least 29.5 in. Hg (as close
to 30 in. Hg as possible). Operate vacuum pump for at least 45
minutes.
3) Close both valves on manifold gauge set. Turn off vacuum
pump. Observe low-side gauge. Any loss of vacuum in 5 minutes
indicates a system leak. Perform leak testing procedure. See LEAK
TESTING. Repair system as necessary and repeat evacuation procedure.
GENERAL MOTORS
Manufacturer recommends using A/C Refrigerant Recovery,
Recycling And Recharging (ACR4) System (J-39500). The ACR4 system ha\
s
one filtering cycle during recovery plus an automatic multiple pass
filtering during evacuation cycle. Follow manufacturer's instructions
provided with ACR4 equipment being used.
JEEP
1) Connect approved recovery/recycling equipment and manifold
gauge set. Fully open manifold gauge set low-side and high-side
valves, and start vacuum pump. Operate vacuum pump until low-side

vacuum reading of 26 in. Hg or more. Close all valves and turn vacuum
pump off. Observe vacuum gauge, go to next step.
2) If A/C system maintains specified vacuum for 5 minutes,
open low-side and high-side valves, restart vacuum pump and operate
for an additional 10 minutes. Close all valves. Turn vacuum pump off
and disconnect pump.
3) If A/C system cannot get to or maintain specified vacuum,
check for a defective vacuum pump or leak in A/C system or gauge set.
See LEAK TESTING. Repair or replace components as necessary.
CHARGING A/C SYSTEM
* PLEASE READ THIS FIRST *
CAUTION: During charging of A/C system, refrigerant container must be
in an upright position. If refrigerant container is
upside down, compressor may be damaged by liquid refrigerant
drawn into A/C system.
CHRYSLER CORP.
Avenger 2.0L & Sebring Coupe 2.0L
1) Ensure A/C system has no leaks and has been evacuated. See
EVACUATING A/C SYSTEM and LEAK TESTING. Locate sight glass on
receiver-drier and ensure it is clean. Close low-pressure adapter
valve and remove from manifold gauge set.
2) Connect low-pressure adapter valve to refrigerant
container and open container valve. Ensure Blue charging hose is
properly connected to vehicle low-pressure service valve. Open adapter
valve.
3) If refrigerant is not drawn in, fully close adapter valve
and check for hose connection leaks. If leak is detected, retighten
connections and repeat A/C system evacuation. See EVACUATING A/C
SYSTEM.
4) If refrigerant is drawn in, start engine. Turn A/C on and
set temperature control to maximum cold and blower motor to low speed.
Operate engine at 1500 RPM. As refrigerant is drawn into system, foam
or bubbles will appear in sight glass.
5) System charge will be close to full when sight glass is
clear, compressor clutch is engaged, and compressor suction and
discharge line temperatures are similar. System charge will be
complete when sight glass is clear, compressor clutch is engaged,
compressor discharge line is warm and suction line is cool.
6) When proper amount of refrigerant has been added, stop
engine. Close refrigerant container and adapter valve, and disconnect
gauge set.
Breeze, Cirrus, Concorde, Intrepid, LHS, Stratus & 300M (Scan
Tool Method)
1) Attach Diagnostic Readout Box (DRB) to Data Link Connecto\
r
(DLC). Set DRB (scan tool) to PARTIAL CHARGE TEST. Attach clamp-on
Thermocouple (80PK-1A) to liquid line, as close to condenser outlet as\
possible.
2) Set parking brake, and place transaxle in Park position.
Start engine and allow to idle. Set A/C controls to outside air, panel
mode, full cool, and high blower speed. Turn A/C on, and open vehicle
windows. Operate A/C system for a few minutes to allow system to
stabilize.
3) Place cardboard over front grille area, to block airflow
through part of condenser, to set A/C system pressure to 260 psi (18.3
kg/cm
). This will stop cooling fans from alternating speeds and
maintain constant pressure.

4) Scan tool will automatically calculate system charge.
Depending on system charge condition, corrections are made 2 ounces at
a time. Each time a correction is made, recheck readings to ensure
proper charge. For system refrigerant capacity, see REFRIGERANT OIL &
REFRIGERANT SPECIFICATIONS article.
Breeze, Cirrus, Concorde, Intrepid, LHS, Stratus & 300M
(Manifold Gauge Set Method)
1) Attach clamp-on Thermocouple (80PK-1A) to liquid line, as\
close to condenser outlet as possible. Attach manifold gauge set to
vehicle.
2) Set parking brake, and place transaxle in Park position.
Start engine and allow to idle. Set A/C controls to outside air, panel
mode, full cool, and high blower speed. Turn A/C on, and open windows.
Operate system for a few minutes to allow system to stabilize.
3) Place cardboard over front grille area, to block airflow
through part of condenser, to set A/C pressure to 260 psi (18.3
kg/cm
). This will stop cooling fans from alternating speeds and
maintain constant pressure.
4) Record temperature reading at liquid line and discharge
pressure reading on gauges. Compare readings with values in
REFRIGERANT CHARGE LEVEL table.
5) Depending on system charge condition, corrections are made
2 ounces at a time. Each time a correction is made, recheck readings
to ensure proper charge. For system refrigerant capacity, see
REFRIGERANT OIL & REFRIGERANT SPECIFICATIONS article.
REFRIGERANT CHARGE LEVEL









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Liquid Line Temp. ( 1) Discharge PressureF (C) psi (kg/cm)
40 (4.4) ........................................... 53-75 (3.7-5.3\
)
60 (15.6) ......................................... 81-104 (5.7-7.3\
)
80 (26.7) ....................................... 111-142 (7.8-10.0\
)
100 (37.8) ..................................... 156-194 (11.0-13.6\
)
120 (48.9) ..................................... 208-259 (14.6-18.2\
)
140 (60.0) ..................................... 272-331 (19.1-23.3\
)
160 (71.1) ..................................... 353-420 (24.8-29.5\
)
180 (82.2) ..................................... 447-516 (31.4-36.3\
)
( 1) - When pressure is lower than specified, system is undercharged.
When pressure is higher than specified, system is overcharged.









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All Other Models
Ensure A/C system has been checked for leaks and evacuated.
See EVACUATING A/C SYSTEM and LEAK TESTING. Charge A/C system to
specifications. For system refrigerant capacity, see REFRIGERANT OIL &
REFRIGERANT SPECIFICATIONS article.
FORD MOTOR CO.
1) If using approved Recovery/Recycling/Charging Center (023-\
00105 or 023-00150), connect to high-side and low-side service valves.
See SERVICE VALVE LOCATIONS under SYSTEM SERVICE VALVES. Operate
charging center according to manufacturer's instructions. Charge
system with specified amount of refrigerant and refrigerant oil. See
REFRIGERANT OIL & REFRIGERANT SPECIFICATIONS article. Check amount of
refrigerant oil in system before adding oil. See COMPRESSOR
REFRIGERANT OIL CHECKING article.
2) If using manifold gauge set, connect to high-side and low-
side service valves. See SERVICE VALVE LOCATIONS under SYSTEM SERVICE

VALVES. Connect 2 hoses with shutoff valves to manifold gauge set
center port. Connect one hose to vacuum pump and other hose to
refrigerant container. Weight of refrigerant container before and
after charging can be used to determine amount of refrigerant drawn
into system. Using vacuum pump, purge air from center hoses.
3) Fully open manifold gauge set low-side valve and
refrigerant container valve to allow refrigerant to enter A/C system.
When no more refrigerant is being drawn into A/C system, start engine
and allow to idle. Select MAX A/C, set blower motor speed to maximum
and allow remaining refrigerant to be drawn into A/C system.
NOTE: When ambient air temperature is high, it may be necessary to
use an external cooling fan to blow air through condenser and
radiator.
4) When proper amount of refrigerant has been added, close
refrigerant container valve. Allow any refrigerant remaining in hose
to be drawn into A/C system. When low-side pressure decreases to about
30 psi (2.1 kg/cm
), close center valve on manifold gauge set. Ensure
A/C system is operating properly. Disconnect manifold gauge set.
Install service port caps. Check system for leaks. See LEAK TESTING.
GENERAL MOTORS
Manufacturer recommends using A/C Refrigerant Recovery,
Recycling And Recharging (ACR4) System (J-39500). The ACR4 system ha\
s
one filtering cycle during recovery plus an automatic multiple pass
filtering during evacuation cycle. Follow manufacturer's instructions
provided with ACR4 equipment being used.
JEEP
Connect recovery/recycling equipment, meeting SAE standard
J1991 or J2210, to vehicle. Charge A/C system to specifications, using
equipment manufacturer's instructions.
LEAK TESTING
TYPES OF LEAK DETECTORS
Bubble Solution Detector
This is a solution applied externally at suspected leak
points. Leaking refrigerant will cause the detector to form bubbles
and foam. A soap and water solution also works well.
Dye Solution
This is a colored solution that may be introduced into the
A/C system. The dye will show up and color components at leak points.
Some manufacturers offer refrigerant containing a Red dye. This dye-
containing refrigerant is installed by normal charging procedures.
Other dye solutions are visible with a Black light only.
Electronic Leak Detector
This instrument will draw in any leaking refrigerant through
a test probe, and then sound an audible signal or create a flashing
light if refrigerant is found. It is the most sensitive of the leak
detectors used. Leak detectors are sensitive to windshield washing
solutions, many solvents and cleaners, and some adhesives. Ensure
surfaces near test areas are clean and dry to prevent false signal or
detector damage. Liquids ingested into detector will damage detector.
See Fig. 24 .

as the malfunction is detected. A stored code indicates there was an
active code present at some time. However, the code currently may not
be present as an active code, although another active code could be.
When a trouble code occurs, the AIR BAG warning light
illuminates for 12 seconds minimum (even if problem existed for less
than 12 seconds). Code is stored, along with time in minutes it was
active, and number of times ignition has been cycled since problem was
detected.
When and if malfunction ceases to exist, an ignition cycle
count will be initiated for that code. If ignition cycle count reaches
100 without a reoccurrence of the same malfunction, DTC is erased and
that ignition cycle counter is reset to zero. If malfunction reoccurs
before count reaches 100, ignition cycle counter will be reset and DTC
will continue to be a stored code.
If a particular code is not active while performing
diagnostic test for that code, code diagnostic test may not locate the
source of the problem. In this case, stored code can only indicate an
area of system to inspect.
If no obvious problems are found, erase stored codes, and
with ignition on, wiggle wiring harness and connectors. Recheck for
codes periodically as you work through system. This procedure may
uncover a difficult problem to locate.
PRETEST INSPECTION & DIAGNOSTIC PROCEDURE
Following precautions and procedures must be followed:
* Always follow air bag service precautions to avoid air bag
deployment and possible personal injury. Refer to procedure
under See SERVICE PRECAUTIONS.
* After component replacement, ensure proper system operation.
See SYSTEM OPERATION CHECK .
* When testing voltage or continuity at ACM, use terminal side
(not wire end) of connector. DO NOT probe wire through
insulation.
* Always check if any TECH SERVICE BULLETINS (TSBs) apply to
vehicle.
* When using diagnostic charts, DO NOT skip any steps in chart
or incorrect diagnosis may result. Always perform
SYSTEM OPERATION CHECK after repairs are made.
* Always use most current DRB diagnostic program cartridge
available to prevent erroneous codes or test results.
* When using diagnostic charts, use DRB voltmeter unless
instructed to use an external voltmeter. Never use a test
light in place of a voltmeter.
* When performing electrical tests, prevent accidental
shorting of terminals. Such shorts can damage fuses or
components and may cause a second code (message) to be
set, making diagnosis of original problem more difficult.
* Vehicle must have a fully-charged battery and functional
charging system.
* Each time a connector is disconnected, inspect it to ensure
it is in good condition. Always focus on circuit being
tested. Dirt, water and corrosion, are most common problems
in connectors.
* Always disconnect DRB after use.
* Always disconnect DRB before charging battery.
USING DRB
1) Refer to DRB user guide for instructions and assistance
with reading trouble codes and other DRB functions. Under normal
operation DRB will display one of only 2 error messages: User-


F - B ASIC T E STIN G - D IE SEL

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Basic Diagnostic Procedures - Trucks - Diesel
Ram Pickup
INTRODUCTION
The following diagnostic steps will help prevent overlooking
a simple problem. This is also where to begin diagnosis for a no-start
condition.
The first step in diagnosing any driveability problem is
verifying the customer's complaint with a test drive under the
conditions the problem reportedly occurred.
Before entering self-diagnostics, perform a careful and
complete visual inspection. Most engine control problems result from
mechanical breakdowns or poor electrical connections. Before
condemning the computerized system, perform each test listed in this
article.
Two different module systems are used for powertrain control
of diesel engine. The Engine Control Module (ECM), located on left
side of engine, is used to control the fuel system. See Fig. 1. The
Fuel Pump Control Module (FPCM) located on pump, is a separate
component of ECM.
The Powertrain Control Module (PCM), located at right rear of\
engine compartment, is used for charging system, transmission and
speed control functions. CCD Bus circuits connect the various vehicle
control modules. These circuits are connected between ECM and PCM to
allow communication between modules.
Fig. 1: Locating Fuel System & Various Engine Components
Courtesy of Chrysler Corp.
PRELIMINARY INSPECTION & ADJUSTMENTS