1999 DODGE RAM check oil

5) Once compressor shaft nut is tightened, check air gap
between clutch plate and pulley surface in at least 4 places. Readjust
air gap if necessary. Install A/C compressor. Evacuate and charge
system. Perform leak test. Ensure A/C system is operating properly.
6) After completing compressor clutch installation, start
engine. Set A/C-heater control to recirculated air mode and high
blower motor speed. Set engine speed to 1500-2000 RPM. Cycle
compressor on for 5 seconds and off for 5 seconds, about 20 times to
break-in clutch.
SHAFT SEAL
Shaft seal is not serviceable. If excessive oil is present on
pulley and plate friction surfaces or on compressor shaft nose area,
replace compressor.
ZEXEL ROTARY VANE
CLUTCH ASSEMBLY
NOTE: Discharging A/C system and removing refrigerant lines from
compressor is not necessary to service clutch assembly.
Removal
1) Loosen tensioner and remove drive belt from pulley.
Disconnect clutch electrical connector. Remove compressor mounting
bolts. With refrigerant lines connected lift compressor upward and
forward. Install one front mounting bolt through bottom rear
compressor mounting ear. Tighten bolt so compressor is supported by
mounting bracket.
2) Using Clutch Drive Plate Holder (SA9510AC), remove clutch\
drive plate center bolt. Insert Clutch Drive Plate Remover Sleeve
(SA9506AC) into center of drive plate. Install remover bolt. While
holding clutch remover sleeve, tighten remover bolt and remove drive
plate and shims.
3) Remove pulley external snap ring. Position Puller Center
Adapter (SA9149AC-2) over end of compressor shaft. Attach 3-jaw puller\
to back of pulley. Tighten puller bolt against pulley center adapter
and remove pulley. Remove clutch coil screws. Disconnect clutch coil
wire. Remove clutch coil.
Installation
1) Install coil in original position. Ensure electrical
connector is aligned with indent in front of compressor head. Tighten
screws to 44 INCH lbs. (5 N.m). Place Drive Plate Installer (SA9149AC\
-
3) and thrust bearing on installation bolt and insert through center
of pulley. Finger-tighten pulley installation bolt into compressor
shaft.
2) Finger-tighten nut on installation bolt to align pulley to
compressor. Hold end of bolt and tighten nut until pulley bottoms on
compressor. Loosen nut and remove installation bolt, thrust bearing
and drive plate installer. Install snap ring with tapered side out.
3) Install thrust bearing on installation bolt and insert
through clutch drive plate. Place original shims on installation bolt.
Thread bolt into compressor shaft. Hold end of bolt and tighten nut
until clutch drive plate bottoms out. Loosen nut and remove
installation bolt and thrust bearing. Install center bolt and tighten
to 115 INCH lbs. (13 N.m) using clutch drive plate holder.
4) Using a feeler gauge, measure air gap between drive plate
and pulley. Air gap should be 0.018-0.030" (0.46-0.76 mm). If air gap
is not as specified, add or remove shims as necessary. Install
compressor onto mounting bracket. Tighten front bolts to 36 ft. lbs.

Refrigerant R-12 based systems use mineral oil, while R-134a
systems use synthetic Polyalkylene Glycol (PAG) oils. Using a mineral
oil based lubricant with R-134a will result in A/C compressor failure
due to lack of proper lubrication.
Following are the most common R-134a refrigerant oils used by
most domestic vehicles:
Chrysler Corp., Eagle & Jeep
Use ND-8 PAG oil, SUN PAG 56 oil, SP-10 PAG Oil, or SP-20 PAG
oil.
Ford Motor Co.
Use YN-12B or YN-12C PAG Refrigerant Oil (specification WSH-
M1C231-B) or SP-20 PAG Oil (specification WST-M1C231-B2).
General Motors
On all models except Saturn, use PAG Refrigerant Oil (Part
No. 12345923). On Saturn, use Saturn PAG refrigerant oil.
NOTE: PAG oil absorbs moisture very rapidly, 2.3-5.6 percent by
weight as compared to a mineral oil absorption rate of .005
percent by weight.
NOTE: Use ONLY the specified oil for the appropriate system or A/C
compressor. Always check the underhood A/C specification
label or A/C compressor label before adding refrigerant oil
to A/C system.
SYSTEM SERVICE VALVES
SCHRADER-TYPE VALVES
NOTE: Although similar in construction and operation to a tire
valve, NEVER replace a Schrader-type valve with a tire
valve.
Schrader valve is similar in construction and operation to a
tire valve. See Fig. 4. When a test gauge hose is attached (hose has
built-in valve core depressor), Schrader stem is pushed inward to the
open position and allows system pressure to reach the gauge.
If test hose being used does not have a built-in core
depressor, an adapter must be used. Never attach hoses or adapters to
a Schrader valve unless it is first connected to manifold gauge set.
Fig. 4: Schrader Service Valve (Compressor Location Shown)
SPECIAL VALVE CONNECTORS
On some General Motors models, thread size on high-side

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.

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









\









\









\









\









\









\









\








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.









\









\









\









\









\









\









\








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

Fig. 24: Electronic Leak Detector
PREPARATION FOR LEAK TESTING
Connect manifold gauge set to air conditioning system. Ensure
low-side and high-side gauge set valves are closed. Check system
pressure. It should be at least 50 psi (3.5 kg/cm
). If system is
empty, evacuate A/C system and apply 28 in. Hg of vacuum. If system
holds vacuum for 15 minutes there most likely are no leaks present. If
low, add just enough refrigerant (about 10 ounces) to bring system to
50 psi (3.5 kg/cm
).
Ensure all joints, connections, and fittings are free of oil
dirt and other contaminants. Using a refrigerant leak detector, check
all refrigerant line connections for leaks. Check condenser and
compressor seal area.
Start engine and allow to idle. Operate A/C system for about
5 minutes. Set A/C controls to outside air, and high blower speed.
Turn A/C on, and open vehicle windows. Turn engine off and wait 2-7
minutes. Refrigerant is heavier than air. Always check for leaks at
bottom of refrigerant lines and components. Refrigerant oil will leak
with refrigerant. Visually check all connections and compressor clutch
area for oil stains. If compressor shaft seal is leaking, a fresh oil
streak will normally be seen on underside of hood, above compressor
clutch.
Always perform leak testing after A/C service. Move
refrigerant leak detector slowly to check for leaks, as leaks will not

be detected if leak testing is performed too quickly.
BUBBLE DETECTOR LEAK TESTING PROCEDURE
This leak detection method is recommended when it is
impossible or difficult to determine the exact location of the leak
using other methods. Although commercial bubble detectors are more
effective, household soap solutions may be used.
Using the dauber that comes with the commercial soap
solution, apply the solution to all joints, connections, fittings or
controls where a leak might be suspected. If high-suds household
solutions are used, apply them with a small brush. Wherever bubbles
form, leaks are present and must be repaired. check the entire system
as there may be more than one leak.
ELECTRONIC LEAK TESTING PROCEDURE
NOTE: Some electronic leak detectors will function on only R-12
systems or on only R-134a systems, and some will function on
both R-12 and R-134a systems. Familiarize yourself with the
tester being used and know what type of system you are leak
testing.
Electronic leak detectors should be used in well ventilated
areas. Avoid using them around explosive gases. Always follow
manufacturer's instructions for the specific tester being used. If
none are available, proceed as follows:
1) Turn all controls and detector sensitivity knob to OFF
position or zero setting. Connect leak detector to an approved source
of power. Turn switch ON, and allow unit to warm up for approximately
5 minutes.
2) Check operation of tester by positioning probe in a
reference source where refrigerant is known to be present in small
amounts. Adjust controls and sensitivity knob until detector reacts
properly. Move probe away from refrigerant source and the reaction
should stop. If it continues, adjust the sensitivity knob to a lower
setting.
3) When tester reacts properly, leak test air conditioning
system by moving probe UNDER all components, fittings and connections.
Keep the probe moving. To check evaporator insert probe into drain
tube opening or a heater duct. DO NOT allow probe to contact
refrigerant or refrigerant oil. When leaks are found, repair them as
necessary. Keep in mind that there may be more than one leak.
DYE SOLUTION LEAK TESTING PROCEDURES
CAUTION: Dye-charged refrigerant cans are available to be used as
internal leak detectors. The use of this type of solution may
void some manufacturer's warranties. Be sure to check with
the A/C system manufacturer concerning the use of dye-charged
leak detectors. Dyes which work in R-12 systems will not work
in R-134a systems.
The following procedure is for introducing a dye solution,
not dye-charged refrigerant, into A/C system.
1) Connect manifold gauge set to air conditioning system in a
normal manner. Remove center hose from manifold gauge set, and replace
it with a short piece (6" long) of 1/4" tubing using two 1/4" flare
nuts. Connect a container of dye solution to the tubing.
2) Connect one end of gauge set center hose to dye solution
container. Connect a container of refrigerant to the other end of the
hose. Operate engine at idle speed. Set the air conditioning system
for maximum cooling. Slowly open the low-side hand valve to allow the

2) If any DTCs listed are present, perform appropriate
test(s). See TORQUE CONVERTOR CLUTCH (TCC) TESTS table. If no DTCs a\
re
present, go to next step.
TORQUE CONVERTOR CLUTCH (TCC) TESTS









\









\









\









\









\









\









\







DTC DTC Message
P0122 (1) ................. THROTTLE POSITION SENSOR VOLTAGE TOO LOW
P0123 ( 1) ................ THROTTLE POSITION SENSOR VOLTAGE TOO HIGH
P1696 ( 1) .......................... PCM FAILURE EEPROM WRITE DENIED
P0743 ........ TORQUE CONVERTOR CLUTCH SOLENOID/TRANS RELAY CIRCUITS
( 2) ........................................................ MISFIRE
P0320 ( 1) ......................... NO CRANK REFERENCE SIGNAL AT PCM
( 1) - See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
( 2) - Perform appropriate misfire DTC test. See appropriate
SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.









\









\









\









\









\









\









\







3) Check transmission fluid for proper level and for any
debris. Fill or repair transmission as necessary. If fluid level and
condition are okay, go to next step.
4) Start engine. Using scan tool, perform TCC SYSTEM TEST. If
vehicle does not stall, go to step 9). If vehicle stalls, go to next
step.
5) Using scan tool, perform GOV and 3-4 SHIFT VALVE SYSTEM
TEST. Select 4th gear. If vehicle stalls, go to next step. If vehicle
does not stall, go to step 7).
6) Turn ignition off. Replace TCC solenoid. Using scan tool,
perform GOV and 3-4 SHIFT VALVE SYSTEM TEST. Select 4th gear. If
vehicle stalls, problem in internal. Check for blocked passage. If
vehicle does not stall, testing is complete.
7) Turn ignition off. Remove oil pump and inspect reaction
shaft, input shaft and input seal. Repair transmission as necessary.
See appropriate AUTOMATIC TRANSMISSION OVERHAUL article. If
transmission is okay, go to next step.
8) Inspect all related wiring and connectors. Repair as
necessary. If wiring and connectors are okay, see INACTIVE DTC
CONDITION under SELF-DIAGNOSTIC SYSTEM. Testing is complete.
9) Turn ignition off. Connect a pressure gauge to
transmission cooler OUT port. Start engine. Using scan tool, perform
TCC SYSTEM TEST. If pressure increases when TCC is actuated, go to
next step. If pressure does not increase, repair leaks or blockage in
hydraulic circuit, or repair valve body as necessary.
10) Turn engine off. Remove oil pump and inspect reaction
shaft, input shaft and input seal. Repair transmission as necessary.
See appropriate AUTOMATIC TRANSMISSION OVERHAUL article. If
transmission is okay, there are no other potential causes remaining.
TCC is assumed to be defective. Replace torque converter.
DTC P0743: TORQUE CONV CLUTCH SOLENOID/TRANS RELAY CKT
NOTE: To test transmission temperature sensor, engine and
transmission temperature must be less than 85F (29C).
Circuit Description
Circuit is monitored continuously while key is on. Code sets
if voltage detected on Torque Converter Clutch (TCC) at the Powertrain\
Control Module (PCM) does not match desired voltage.
Possible Causes

replace PCM and see INACTIVE DTC CONDITION under SELF-DIAGNOSTIC
SYSTEM. Testing is complete.
DTC P0783: 3-4 SHIFT SOL, NO RPM DROP @ 3-4 SHIFT
Circuit Description
Circuit is monitored continuously while key is on and engine
running. Code sets if expected RPM drop does not occur within 4
seconds of requested gear change by PCM. Test must fail 3 times to set
code.
Possible Causes
* Transmission mechanically defective.
* TPS codes set.
* Transmission 3-4 solenoid wiring harness defective.
* Transmission fluid burnt or oil pan has excessive debris.
Diagnostic Procedures
1) Using scan tool, read DTCs. On all bodies except AB and WJ
bodies, go to next step. On AB and WJ bodies, if DTC SPECIFIC GOOD
TRIPS counter is not displayed or displayed count is not "0", go to
step 6). If DTC SPECIFIC GOOD TRIPS counter is displayed and displayed
count is "0", indicating DTC still exists, go to next step.
2) If any DTCs listed are present, perform appropriate
test(s). See 3-4 SHIFT SOLENOID TESTS table. If no DTCs are present,
go to next step.
3-4 SHIFT SOLENOID TESTS









\









\









\









\









\









\









\







DTC Message Test
NO CAM SIGNAL AT PCM ..................................... ( 1) P0340
P/N SWITCH STUCK IN PARK OR IN GEAR .......................... P1899
Any Throttle Position Sensor (TPS) DTC ......................... ( 1)
TORQUE CONVERTOR CLUTCH SOLENOID/TRANS RELAY CIRCUITS ........ P0743
TRANS 12-VOLT SUPPLY RELAY CNTRL CIRCUIT ..................... P1765
TRANS 3-4 SHIFT SOLENOID/TRANS RELAY CIRCUITS ................ P0753
( 1) - See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.









\









\









\









\









\









\









\







3) Check transmission fluid for proper level and for any
debris. Fill or repair transmission as necessary. If fluid level and
condition are okay, go to next step.
4) Connect a 0-300 psi (0-21 kg/cm
) pressure gauge to
transmission Overdrive (O/D) clutch pressure test port. Connect a
second 0-300 psi (0-21 kg/cm
) pressure gauge to transmission governor
pressure test port. See appropriate AUTOMATIC TRANSMISSION OVERHAUL
article. Ensure engine and transmission are at normal operating
temperature. With an assistant, test drive vehicle. Using scan tool,
select GOV and 3-4 SHIFT VALVE SYSTEM TEST. Select 4th gear while
monitoring pressure gauge. Governor pressure should rise to greater
than 20 psi (1.4 kg/cm
) and O/D pressure should rise to greater than
40 psi (2.8 kg/cm). If pressures are as specified, go to next step.
If pressures are not as specified, go to step 8).
5) Using wiring diagram as a guide, inspect wiring and
connectors. Repair wiring harness as necessary. If wiring and
connectors are okay, go to next step.
6) Using scan tool, erase DTCs. Start engine. Road test
vehicle at 0-55 MPH with a constant 20 percent throttle. Repeat road
test 4 times. Note if DTC P0783 resets. If DTC P0783 resets, repair
wiring harness as necessary. If DTC P0783 does not reset, go to next