1999 DODGE RAM oil

install, reverse removal procedure.
Removal & Installation (Ram Pickup - Front)
Blower motor resistor is located under glove box, attached to
blower motor housing. See Fig. 5. Disconnect negative battery cable.
Remove blower motor resistor connector. Remove resistor retaining
screws. Remove blower motor resistor. To install, reverse removal
procedure.
BLOWER MOTOR SWITCH (REAR)
Removal & Installation (Durango)
Disconnect negative battery cable. Pry above indentations at
outer perimeter of rear blower motor switch. Pull rear blower motor
switch and disconnect electrical connector. Remove rear blower motor
switch. To install, reverse removal procedure.
COMPRESSOR
Removal & Installation
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
refrigerant lines and plug or cover all openings in A/C system.
2) Remove drive belt. Disconnect compressor electrical leads.
Remove compressor mounting nuts and bolts. Remove compressor. Drain
oil from compressor, and record amount of oil drained.
3) To install, reverse removal procedure. Using new
refrigerant oil, add to compressor the same amount of oil drained from
it. Evacuate and charge A/C system.
CONDENSER
NOTE: Before removing condenser, note location of radiator and
condenser air seals. If air seals are not installed properly,
A/C and engine cooling systems will not perform properly.
Removal
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
A/C fittings at inlet and outlet of condenser. Plug or cover all
openings in A/C system.
2) On Dakota, remove bolts securing radiator and fan shroud
to inside of upper radiator crossmember. Remove top mounting bolts
securing condenser to upper crossmember. Tilt top of radiator and fan
shroud toward engine.
3) On Ram Pickup (gasoline engine), remove bolts securing
condenser upper mounting brackets to outside of upper radiator
crossmember. Tilt condenser away from engine compartment far enough to
grasp top of condenser with both hands. On Ram Pickup (diesel engine),\
remove bolts securing condenser to charge air cooler. On all models,
lift condenser assembly from vehicle.
Installation
To install, reverse removal procedure. Install new "O" rings
to fittings. Fill cooling system. Evacuate and charge A/C system.
EVAPORATOR CORE & HEATER CORE
Removal & Installation (Dakota & Durango - Front)
Remove instrument panel. See INSTRUMENT PANEL. Remove A/C-
heater assembly. See A/C-HEATER ASSEMBLY. With A/C-heater housing
removed, remove housing cover. Remove evaporator core or heater core

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
A/C Compressor Mounting Bolts .............................. 20 (27)\
A/C Compressor Suction/Discharge Hose ...................... 17 (23)\
Service Valve-To-Compressor Fitting .................... ( 1) 35 (47)
INCH Lbs. (N.m)
Compressor Oil Filler Plug ................................ 84 (9.5)\
A/C-Heater Housing Mounting Nuts (Front) .................... 60 (7\
)
A/C-Heater Housing Mounting Screws (Rear) ................. 106 (12\
)
( 1) - Wet torque fitting. Lubricate service valve coupling threads and
"O" rings with refrigerant oil.









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VACUUM DIAGRAMS
Fig. 9: Manual A/C-Heater System Vacuum Diagram (Dakota & Durango)
Courtesy of Chrysler Corp.


A/C -H EA TE R S YSTE M T R O UBLE S H O OTIN G

1999 D odge P ic ku p R 1500
1999 MANUAL A/C-HEATER SYSTEMS
Trouble Shooting - Cars & Trucks
CHRYSLER
Avenger, Breeze, Caravan, Cirrus, Concorde, Dakota, Durango,
Intrepid, LHS, Neon, Ram Pickup, Ram Van/Wagon, Sebring Convertible,
Sebring Coupe, Stratus, Town & Country, Voyager, 300M
A/C SYSTEM DIAGNOSIS
RAPID COMPRESSOR CLUTCH CYCLING
Some possible causes of rapid compressor clutch cycling,
clutch cycles 10 or more times per minute, include:
* Low refrigerant system charge.
* Faulty low pressure cycling clutch switch.
* Faulty PCM.
COMPRESSOR WILL NOT ENGAGE
Some possible causes of compressor not engaging with high and
low side system pressures equal include:
* No refrigerant in system.
* Faulty fuse.
* Faulty compressor clutch coil.
* Faulty compressor clutch relay.
* Faulty electronic cycling clutch switch.
* Improperly installed or faulty low pressure cycling clutch
switch.
* Faulty low pressure cut-off switch.
* Faulty high pressure cut-off switch.
* Faulty PCM.
* Faulty A/C-heater control panel.
TEMPERATURE IS TOO HIGH WITH A/C ON
Some possible causes of high temperature output at center
panel when A/C system pressure is normal include:
* Excessive oil charge in refrigerant.
* Temperature control cable improperly installed or faulty.
* Blend-air door inoperative, obstructed or sealing
improperly.
* Blend door actuator not calibrated.
LOW SIDE PRESSURE IS LOW-TO-NORMAL & HIGH SIDE PRESSURE IS
LOW
Some possible causes of low side system pressure being lower-
to-normal and high side system pressure being too low include:
* Low refrigerant system charge.
* Refrigerant flow through accumulator is restricted.
* Refrigerant flow through evaporator is restricted.
* Faulty compressor.
LOW SIDE PRESSURE IS HIGH-TO-NORMAL & HIGH SIDE PRESSURE IS

of underhood labels with R-134a refrigerant clearly printed on labels.
See Fig. 2 . The underhood label used on Ford Motor Co. vehicles is
Yellow. See Fig. 3. Most manufacturers will identify refrigerant type
with labels affixed to compressor. Before servicing an A/C system,
always determine which refrigerant is being used.
Fig. 2: Underhood Refrigerant Identification Labels (Typical)
Courtesy of chrysler corp.
Fig. 3: Underhood Refrigerant Identification Label (Typical)
Courtesy of ford motor co.
REFRIGERANT OILS

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

ORIFICE TUBE REPLACEMENT
CHRYSLER CORP.
Removal & Installation (Dakota)
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
liquid line at condenser outlet tube. Cover open refrigerant fittings
to protect from moisture and dirt.
2) Using 2 wrenches, loosen tube fitting and separate front
half of liquid line from rear half of liquid line. Using needle nose
pliers, remove fixed orifice tube from rear half of liquid line. Note
fixed orifice tube orientation for correct installation.
3) To install, reverse removal procedure. Ensure fixed
orifice tube is positioned correctly. Evacuate, charge, and leak test
A/C system. Ensure A/C system operates properly.
NOTE: On Ram Pickup, if the fixed orifice tube is faulty or
plugged, the liquid line and orifice tube must be replaced as
an assembly.
Removal & Installation (Ram Pickup)
Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
liquid line from evaporator inlet and condenser outlet tubes. Cover
open refrigerant fittings to protect from moisture and dirt.
Disconnect liquid line retaining clips. Remove liquid line and orifice
tube. To install, reverse removal procedure. Evacuate, charge, and
leak test A/C system. Ensure A/C system operates properly.
FORD MOTOR CO.
NOTE: Replace orifice tube whenever compressor is replaced. Fixed
orifice tube is located in the condenser-to-evaporator liquid
line.
NOTE: DO NOT use pliers to remove fixed orifice tube or twist
orifice tube in liquid line. Doing so will cause plastic
orifice tube body to break inside condenser-to-evaporator
liquid line.
Fixed Orifice Tube Replacement (Except Continental, Mustang &
Villager)
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. On Contour
and Mystique, move power steering fluid reservoir to one side without
disconnecting hoses.
2) On all models, disconnect condenser-to-evaporator
discharge (liquid) line. Remove and discard "O" rings from line. Pour
a small amount of refrigerant oil into inlet to lubricate orifice "O"
rings.
3) Insert orifice tube remover/installer into tube and turn
tool to right to engage tangs on orifice tube. See Fig. 18. Hold "T"
handle of tool and slowly tighten nut down onto discharge line to
slowly pull orifice tube out. If orifice tube breaks off when removal
is attempted, use orifice tube extractor to pull the broken section
out. See Fig. 19.
4) Ensure replacement orifice tube is fitted with "O" ring(s)\
lubricated with clean refrigerant oil. Insert tube with short end
toward evaporator, until seated. Reconnect high pressure line. On
Contour and Mystique, tighten connection to 18 ft. lbs. (24 N.m).

Fig. 19: Removing Broken Orifice Tube (Typical)
Courtesy of ford motor co.
NOTE: On Continental, Mustang and Villager, if orifice tube is
faulty or plugged, liquid line and orifice tube must be
replaced as an assembly or an orifice tube replacement kit
must be installed.
Orifice Tube Replacement Kit (Continental & Mustang)
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove condenser-to-evaporator liquid
line from vehicle. Locate orifice tube in metal portion of liquid
line, near bend (indented notches or circular depression). See Fig. 20
.
2) Cut a 2.5" (63.5 mm) section from liquid line, at least 1\
"
(25.4 mm) from start of bend in line and discard. Clean out liquid
line to remove contaminants.
3) Lubricate orifice tube replacement kit compression nuts
and rings with refrigerant oil and install on liquid line. See Fig. 21
. Ensure flow direction arrow points toward evaporator. Ensure liquid
line is properly aligned for installation. Tighten compression nuts to
65-69 ft. lbs. (88-94 N.m).
4) To complete installation, reverse removal procedure.
Lubricate "O" rings with refrigerant oil. Evacuate, charge and leak

test system. Ensure A/C system is operating properly.
Orifice Tube Replacement Kit (Villager)
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Drain engine coolant to a level below
thermostat. Remove upper radiator hose and bracket to gain access to
condenser end of liquid line. Remove condenser-to-evaporator liquid
line from vehicle.
2) Locate orifice tube in metal portion of liquid line, at
indentation. See Fig. 20. Make a 4" (102 mm) index line on liquid line
with indentation at the midpoint. Cut a 2.5" (63.5 mm) section from
liquid line with indentation in the middle, at least 1" (25.4 mm) from\
start of closest bend. Clean out liquid line to remove contaminants.
3) Lubricate orifice tube replacement kit compression nuts
and rings with refrigerant oil and install on liquid line. See Fig. 21
. Ensure flow direction arrow points toward evaporator. Ensure index
line on liquid line is properly aligned for installation. Tighten
compression nuts to 65-70 ft. lbs. (88-95 N.m).
4) To complete installation, reverse removal procedure.
Lubricate "O" rings with refrigerant oil. Evacuate, charge and leak
test system. Ensure A/C system is operating properly.
Fig. 20: Locating Orifice Tube (Continental & Mustang Shown; Villager
Is Similar)
Courtesy of ford motor co.