1999 DODGE RAM engine


A/C C O M PR ESSO R S ER VIC IN G
1999 D odge P ic ku p R 1500
1999 GENERAL SERVICING
A/C Compressor Servicing
All Models
* PLEASE READ THIS FIRST *
NOTE: Always refer to underhood A/C specification label in engine
compartment or A/C compressor label while servicing A/C
system. If A/C specification label and A/C COMPRESSOR
SERVICING article specifications differ, use underhood label
specifications.
BODY DESIGNATIONS
BODY DESIGNATIONS (CHRYSLER CORP. CARS)








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Model ( 1) Body Designation
Avenger & Sebring Coupe ................................ "FJ22" Body
Breeze, Cirrus & Stratus ................................. "JA" Body
Concorde, Intrepid, LHS & 300M ........................... "LH" Body
Neon ..................................................... "PL" Body
Sebring Convertible ...................................... "JX" Body
( 1) - Body codes are determined by fifth character of VIN code.









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BODY DESIGNATIONS (CHRYSLER CORP. LIGHT TRUCKS & VANS)








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Model Body Designation
Caravan, Town & Country, & Voyager ..................... "NS" Series
Dakota ................................................. "AN" Series
Durango ................................................ "DN" Series
Ram Pickup .......................................... "BR/BE" Series
Ram Van/Wagon .......................................... "AB" Series









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BODY DESIGNATIONS (FORD MOTOR CO. LIGHT TRUCKS & VANS)








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Model Body Designation
Explorer & Mountaineer .................................. "U" Series
Pickup .................................................. "F" Series
Ranger .................................................. "R" Series
Van ..................................................... "E" Series









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BODY DESIGNATIONS (GENERAL MOTORS CARS)








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Model ( 1) Body Designation
Alero, Cutlass, Grand Am & Malibu ......................... "N" Body
Aurora & Riviera .......................................... "G" Body
Bonneville, Eighty Eight, LeSabre & LSS ................... "H" Body
Camaro & Firebird ......................................... "F" Body
Catera .................................................... "V" Body
Cavalier & Sunfire ........................................ "J" Body

General Motors (1)
"C" Body ...................................... Harrison V5 5-Cyl.
"E" Body ................................. Harrison HD6/HT6 6-Cyl.
"F" Body
3.8L Engine ................................. Harrison V5 5-Cyl.
5.7L Engine ................................. Harrison V7 7-Cyl.
"G" Body
Aurora ................................. Harrison HD6/HT6 6-Cyl.
Riviera ..................................... Harrison V5 5-Cyl.
"H" Body ...................................... Harrison V5 5-Cyl.
"J" Body ...................................... Harrison V5 5-Cyl.
"K" Body ................................. Harrison HD6/HT6 6-Cyl.
"M" Body ..................................... Nippondenso 10-Cyl.
"N" Body ...................................... Harrison V5 5-Cyl.
"S" Body ...................................... Harrison V5 5-Cyl.
"V" Body ...................................... Harrison V5 5-Cyl.
"W" Body ...................................... Harrison V5 5-Cyl.
"Y" Body ...................................... Harrison V7 7-Cyl.
"Z" Body ....................................... Zexel Rotary Vane
( 1) - Body codes are determined by fourth character of VIN code.









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COMPRESSOR APPLICATIONS (LIGHT TRUCKS & VANS)








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Application Compressor
Chrysler Corp.
Dakota & Ram Pickup ........................ Sanden SD-7H15 7-Cyl.
Durango .................................... Sanden SD-7H15 7-Cyl.
Caravan, Town & Country, & Voyager .... Nippondenso 10PA17 10-Cyl.
Ram Van/Wagon ............................... Sanden TR-105 Scroll
Ford Motor Co.
"E" Series Van ................................ Ford FS-10 10-Cyl.
Expedition & Navigator ........................ Ford FS-10 10-Cyl.
Explorer & Mountaineer ........................ Ford FS-10 10-Cyl.
"F" Series Pickup
Except Super Duty ........................... Ford FS-10 10-Cyl.
Super Duty ............................... Sanden SD-7H15 7 Cyl.
Ranger ........................................ Ford FS-10 10-Cyl.
Villager ........................................... FS-10 10-Cyl.
Windstar ...................................... Ford FS-10 10-Cyl.
General Motors ( 1)
"C" & "K" Series ......................... Harrison HD6/HT6 6-Cyl.
"G" Series .................................... Harrison V5 5-Cyl.
"J" Series ................................... Nippondenso 10-Cyl.
"L" & "M" Series ......................... Harrison HD6/HT6 6-Cyl.
"P" Series ............................... Harrison HD6/HT6 6-Cyl.
"S" & "T" Series
2.2L ........................................ Harrison V7 7-Cyl.
4.3L ................................... Harrison HD6/HT6 6-Cyl.
"U" Series .................................... Harrison V5 5-Cyl.
Jeep
Cherokee ................................... Sanden SD-7H15 7-Cyl.
Grand Cherokee ........................ Nippondenso 10PA17 10-Cyl.
Wrangler ................................... Sanden SD-7H15 7-Cyl.
( 1) - Series codes are determined by fifth character of VIN code.









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FORD FS-10 10-CYLINDER

CLUTCH ASSEMBLY
Removal (Except Grand Cherokee)
Remove compressor shaft bolt. Remove clutch plate and shims.
Tighten a 10-mm bolt into clutch hub bolt hole to remove clutch hub
and shims. Remove snap ring, and remove rotor and pulley assembly.
Remove snap ring, and disconnect clutch coil lead. Remove clutch coil.
Installation
1) Install clutch coil so pin in back of coil aligns with
hole in front compressor housing. Connect clutch coil lead. Install
snap ring with bevel side facing outward. Ensure snap ring is properly
seated in groove. Install rotor and pulley assembly. Install shims and
snap ring. Install clutch hub.
2) Install dial indicator at front of clutch hub to measure
clutch hub air gap. Using battery voltage, energize clutch coil.
Proper air gap is 0.014-0.026" (0.35-0.65 mm). Add or remove shims to
obtain correct air gap. Install compressor shaft bolt. On Concord and
Intrepid, tighten compressor shaft bolt to 11-15 ft. lbs. (15-20 N.m).\
On all other models, tighten compressor shaft bolt to 10 ft. lbs. (14
N.m).
NOTE: On Grand Cherokee, compressor clutch can be serviced in
vehicle without discharging A/C system.
Removal (Grand Cherokee)
Disconnect and isolate negative battery cable. Remove
serpentine drive belt. Remove compressor shaft bolt. Using a plastic
mallet, tap clutch plate to loosen from compressor shaft. Remove
clutch plate, shaft key and shims. See Fig. 5. Remove snap ring, and
remove pulley assembly. Remove snap ring, and disconnect clutch coil
lead. Remove clutch coil.
Installation
1) Install clutch coil so pin in back of coil aligns with
hole in front compressor housing. Connect clutch coil lead. Install
snap ring with bevel side facing outward. Ensure snap ring is properly
seated in groove. Align snap ring eyelets to the left or right of
clutch coil pin. Install rotor and pulley assembly. Install shims and
snap ring. Install clutch hub.
2) Hold clutch plate tight against shims and measure air gap
between clutch plate and pulley face. Air gap should be 0.014-0.026"
(0.35-0.65 mm). Add or remove shims as necessary. Install compressor
shaft bolt. Tighten compressor shaft bolt to 115 INCH lbs. (13 N.m).
To complete installation, reverse removal procedure.
3) 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
NOTE: Shaft seal replacement procedure is for 10PA17C compressor.
Shaft seal replacement procedure for 10PA17 compressor is not
available.
Removal
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove A/C compressor. Drain oil from
compressor, and measure amount drained. Remove clutch hub, shims,
rotor and pulley assembly, and clutch coil. See CLUTCH ASSEMBLY. See

Fig. 6: Compressor Components (Sanden MSC90-C Scroll)
Courtesy of chrysler corp.
SANDEN SD-7H15 7-CYLINDER
NOTE: On Cherokee, Dakota, Durango, Ram Pickup and Wrangler,
compressor clutch can be serviced in vehicle, without
discharging A/C system.
CLUTCH ASSEMBLY
Removal (Cherokee, Dakota, Durango, Ram Pickup & Wrangler)
1) Disconnect and isolate negative battery cable. Remove
serpentine drive belt. Disconnect clutch coil harness connector.
Without disconnecting refrigerant lines, remove A/C compressor from
mounting bracket. Support compressor in engine compartment.
2) Using spanner wrench, hold clutch plate and remove
compressor shaft nut. See Fig. 1. Using a steering wheel puller,
remove clutch plate, compressor shaft key and shims. Remove external
front housing snap ring.
3) Install jaws of Rotor Puller (C-6141-1) into pulley snap
ring groove. Install Shaft Protector (C-6141-2) over compressor shaft.\
Install puller flange plate on jaws. Install Puller Through-Bolts (C-
6461) through puller flange plate into jaws and hand tighten. Tighten
pulley center bolt clockwise and remove pulley from compressor.
4) Remove clutch coil wire harness retainer from compressor
housing. Remove clutch coil snap ring and clutch coil.

Installation (Cherokee & Wrangler)
1) Install clutch coil and clutch coil snap ring. Install
clutch coil wire harness to compressor housing. Align pulley and
bearing assembly on front compressor housing hub. Using Installer (C-
6871), press pulley and bearing assembly onto compressor housing hub.
Thread installer on compressor shaft and tighten nut until pulley
assembly is seated.
2) Install external front snap ring with beveled side facing
outward. Ensure snap ring is properly seated. Install compressor shaft
key and original shims. Using a plastic mallet and Driver (C-6463),
install clutch plate on compressor shaft. Tighten compressor shaft nut
to 10 ft. lbs. (14 N.m).
3) Using feeler gauge, measure air gap between clutch plate
and pulley assembly in several areas. Air gap should be 0.016-0.031"
(0.41-0.79 mm). If air gap is not within specification, adjust shim
thickness as necessary. If air gap is not consistent around clutch
plate, lightly pry up or tap down on clutch plate to make corrections.
To complete installation, reverse removal procedure.
Installation (Dakota, Durango & Ram Pickup)
1) Install clutch coil and clutch coil snap ring. Install
clutch coil wire harness to compressor housing. Align pulley and
bearing assembly on front compressor housing hub.
2) Install Handle (6464) and Driver (6143) into pulley
assembly bearing cavity. Ensure outer edge of driver rests firmly on
inner race of bearing. Using hammer, install pulley and bearing
assembly. While tapping on handle, guide pulley and bearing assembly
to prevent binding. Ensure pulley assembly bottoms against compressor
housing. Install external snap ring.
3) Install original shim(s) and compressor shaft key. Use a
hammer and Shaft Protector (6141-2) to install clutch plate on
compressor shaft. Ensure clutch plate bottoms out on clutch shims.
Replace compressor shaft nut and tighten compressor shaft nut to 10
ft. lbs. (14 N.m).
4) Measure air gap between clutch plate and pulley assembly
in several areas. Air gap should be 0.016-0.031" (0.41-0.79 mm). If
air gap is not within specification, adjust shim thickness as
necessary. If air gap is not consistent around clutch plate, lightly
pry up or tap down on clutch plate to make corrections. To complete
installation, reverse removal procedure. Ensure A/C system operates
properly.
5) 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.
Removal (Ford "F" Series Super Duty Pickup)
1) Disconnect and isolate negative battery cable. Discharge
A/C system, using approved refrigerant recovery/recycling equipment.
Disconnect clutch coil harness connector and remove compressor. Drain
oil from compressor, and measure amount drained.
2) Using Spanner Wrench (T70P-4067-A), hold clutch plate and\
remove compressor shaft nut. See Fig. 1. If necessary, use a steering
wheel puller to remove clutch plate and shim(s).
3) Using a flat-blade screwdriver, remove pulley assembly
bearing dust cover. Remove compressor shaft key and internal bearing
snap ring. Remove external front housing snap ring.
4) Install jaws of rotor puller into pulley assembly internal
bearing snap ring groove. Install shaft protector over compressor
shaft. Install puller flange plate on jaws. Install 2 puller bolts
through puller flange plate into jaws and hand tighten. Tighten pulley
center bolt clockwise and remove pulley assembly from compressor.

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\
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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.

HIGH
Some possible causes of low side system pressure being high-
to-normal and high side system pressure being too high include:
* Condenser air flow restricted.
* Inoperative cooling fan.
* Faulty expansion valve.
* Refrigerant system overcharged.
* Air in refrigerant system.
* Engine overheating.
LOW SIDE PRESSURE IS HIGH & HIGH SIDE PRESSURE IS LOW
Some possible causes of low side system pressure being too
high and high side system pressure being too low include:
* Compressor belt is slipping.
* Fixed orifice tube not installed.
* Faulty compressor.
LOW SIDE PRESSURE IS LOW & HIGH SIDE PRESSURE IS HIGH
Some possible causes of low side system pressure being too
low and high side system pressure being too high include:
* Restricted refrigerant flow through refrigerant lines.
* Restricted refrigerant flow through expansion valve.
* Restricted refrigerant flow through fixed orifice tube.
* Restricted refrigerant flow through receiver-drier.
* Restricted refrigerant flow through condenser.
BLOWER MOTOR DIAGNOSIS
BLOWER MOTOR INOPERATIVE
Some possible causes of an inoperative blower motor include:
* Faulty fuse.
* Faulty blower motor feed circuit wire harness or
connectors.
* Faulty blower motor ground circuit wire harness or
connector.
* Faulty blower motor resistor.
* Faulty blower motor relay.
* Faulty blower motor switch.
* Faulty A/C-heater mode control switch.
* Faulty blower motor.
BLOWER NOT OPERATING IN ALL SPEEDS
Possible causes of the blower not operating in all speeds
include:
* Faulty fuse.
* Faulty blower motor feed circuit wire harness or
connectors.
* Faulty blower motor relay.
* Faulty blower motor resistor.
* Faulty blower motor switch.

BLOWER MOTOR VIBRATION
Possible causes of blower motor vibration include:
* Improper blower motor mounting.
* Improper blower wheel or fan mounting.
* Blower wheel or fan out of balance.
* Blower motor faulty.
BLOWER MOTOR NOISE
Possible causes of blower motor noise include:
* Foreign material in blower motor housing.
* Foreign material in A/C-heater housing.
* Improper blower motor mounting.
* Improper blower wheel or fan mounting.
* Blower motor faulty.
VACUUM CONTROL SYSTEM DIAGNOSIS
VACUUM CONTROL ONE-WAY CHECK VALVE
NOTE: Some models use brake booster check valve for vacuum source.
These models do not use another in-line vacuum check valve.
1) In engine compartment, locate Black vacuum hose that runs
from brake booster check valve or intake manifold, through firewall
near heater hoses or expansion valve. This supply vacuum hose goes to
A/C-heater control panel vacuum switch.
2) Within Black vacuum hose, disconnect and remove check
valve near intake manifold or brake booster. Connect vacuum gauge to
an external vacuum pump. Start vacuum pump. Plug end of hose probe on
vacuum gauge. Adjust bleed valve on vacuum gauge to obtain an exact
vacuum reading of 8 in. Hg.
3) Unplug and plug end of hose probe on vacuum gauge several
times to ensure exact vacuum reading. Connect vacuum gauge hose probe
to control panel side of check valve. Vacuum gauge reading should be 8
in. Hg. Replace check valve if vacuum leak exists.
4) Connect vacuum gauge hose probe to engine side of check
valve. Vacuum should flow through check valve. Replace check valve if
operation is not as described.
VACUUM CONTROLS
1) This test checks for proper function of control panel
vacuum circuits. Perform steps 1) through 4) under VACUUM CONTROL ONE-\
WAY CHECK VALVE.
2) Connect vacuum gauge hose probe to Black vacuum hose end
that leads to A/C-heater control panel switch. Position vacuum gauge
so gauge reading can be observed from inside vehicle.
3) Operate A/C-heater controls (sliding lever or push
buttons) in all mode positions (floor, defrost, panel, etc.). Pause
after each selection to allow vacuum actuators or motors to energize
and stabilize. Record vacuum gauge reading at each selection.
4) After each selection, vacuum reading should be 7.5-8 in.
Hg. Maximum vacuum reading drop is .75 in. Hg. If proper vacuum
reading cannot be obtained, vacuum leak exists in selected circuit.
5) To check for vacuum leak(s), disconnect 7-way A/C-heater
control panel vacuum harness connector. See Fig. 1. If necessary,
remove control panel from instrument panel to access A/C-heater
control panel vacuum harness connector, or remove lower instrument