1999 DODGE RAM oil

evaporator inlet line and "O" rings with refrigerant oil. Lubricate
orifice tube and "O" ring with refrigerant oil. Insert orifice tube
into evaporator inlet line with short screen toward condenser.
2) Tighten liquid line nut to 18 ft. lbs. (24 N.m). To
complete installation, reverse removal procedure. Evacuate, charge,
and test system for proper operation.
Removal ("F" Body)
Discharge A/C system, using approved recovery/recycling
equipment. Disconnect negative battery cable. Disconnect A/C pressure
switch connector. Use a backup wrench to hold evaporator fitting, and
loosen evaporator liquid line fitting. Remove bolt. Disconnect
evaporator liquid line. Remove and discard "O" rings. Using needle-
nose pliers, remove orifice tube from evaporator inlet line.
Installation
1) Clean evaporator line fitting with refrigerant oil. Coat
inside of inlet line and evaporator line "O" rings with refrigerant
oil. Lubricate orifice tube and "O" ring with refrigerant oil and
insert them into inlet line. Insert orifice tube into evaporator inlet
line with long screen inlet end toward condenser.
2) Tighten bolt to 12 ft. lbs. (16 N.m). Tighten evaporator
line fitting to 28 ft. lbs. (38 N.m). To complete installation,
reverse removal procedure. Evacuate, charge, and test system for
proper operation.
Removal ("J" & "N" Body)
1) Locate orifice tube. See ORIFICE TUBE LOCATION &
REMOVER/INSTALLER APPLICATION table. Discharge A/C system, using
approved recovery/recycling equipment. On "J" body, remove upper
closeout panel. On "N" body, raise and support vehicle. On all models,
disconnect condenser-to-evaporator line at condenser outlet and
discard "O" rings.
2) Disconnect condenser-to-evaporator line clip on right side
body rail, behind engine mount. Remove orifice tube using Orifice Tube
Remover/Installer (J-26549-E) or needle-nose pliers.
3) If difficulty is encountered during removal of a plugged
or restricted orifice tube, remove as much residue as possible. Using
a heat gun, carefully apply heat 1/4" from dimples on condenser inlet
line. Be careful not to overheat line.
4) If A/C pressure switch is located near orifice tube,
remove switch to protect it from heat. While heat is being applied,
grip orifice tube using orifice tube remover/installer or needle-nose
pliers. Use a turning motion along with a push-pull motion to loosen
and remove orifice tube.
Installation
1) Coat inside of condenser inlet line and "O" rings with
refrigerant oil. Lubricate orifice tube "O" ring with refrigerant oil
and insert into condenser inlet line. Insert orifice tube into
condenser inlet line with shorter screen toward evaporator.
2) Connect condenser-to-evaporator line clip on right side
body rail. Lubricate "O" rings and connect condenser inlet line.
Tighten condenser inlet line nut to 12 ft. lbs. (16 N.m). Install
closeout panel. Evacuate, charge, and test system for proper
operation.
Removal ("W" Body)
1) Locate orifice tube. See ORIFICE TUBE LOCATION &
REMOVER/INSTALLER APPLICATION table. Remove air cleaner and duct
assembly. Discharge A/C system, using approved recovery/recycling
equipment. Disconnect negative battery cable. Disconnect ABS modulator
and A/C pressure sensor/fan switch electrical connectors.

2) Disconnect liquid line/suction line bracket. Disconnect
liquid line at orifice tube. Remove orifice tube using specified
orifice tube remover/installer. See ORIFICE TUBE LOCATION &
REMOVER/INSTALLER APPLICATION table.
3) If difficulty is encountered during removal of a plugged
or restricted orifice tube, remove as much residue as possible. Using
a heat gun, carefully heat inlet line. If inlet line has small
dimples, apply heat 1/4" from dimples. Be careful not to overheat
line.
4) If A/C pressure switch is located near orifice tube,
remove switch to protect it from heat. While heat is being applied,
grip orifice tube using needle-nose pliers. Use a turning motion along
with a push-pull motion to loosen and remove orifice tube.
Installation
1) Coat inside of inlet line and "O" ring with refrigerant
oil. Lubricate orifice tube and "O" ring with refrigerant oil and
insert them into inlet line. Insert orifice tube into evaporator inlet
line with short screen toward condenser.
2) Tighten liquid line fitting at orifice tube to 20 ft. lbs.
(27 N.m). To complete installation, reverse removal procedure.
Evacuate, charge, and test system for proper operation.
Removal ("C" & "K" Series)
1) Discharge A/C system, using approved recovery/recycling
equipment. On models equipped with front A/C system only, remove front
grille. Using a backup wrench, loosen condenser-to-evaporator (liquid)\
line fitting at condenser and disconnect line.
2) On models equipped with rear A/C system, loosen condenser-
to-evaporator (liquid) line fitting between junction block and
evaporator. If necessary, remove air cleaner assembly.
3) On all models, remove and discard fitting "O" ring. Using
Orifice Tube Remover/Installer (J-26549-E), remove orifice tube from
liquid line. If difficulty is encountered during removal of a plugged
or restricted orifice tube, remove as much residue as possible.
4) Using a heat gun, carefully apply heat 1/4" from dimples
on liquid line. Be careful not to overheat line. If A/C pressure
switch is located near orifice tube, remove switch to protect it from
heat.
5) While heat is being applied, grip orifice tube using
orifice tube remover/installer. Use a turning motion along with a
push-pull motion to loosen and remove orifice tube.
Installation
1) Clean liquid line fitting with refrigerant oil. Coat
inside of liquid line and "O" ring with refrigerant oil. Lubricate
orifice tube and "O" ring with refrigerant oil and insert them into
liquid line. Insert longer orifice tube screen (inlet end) into
condenser outlet line first, toward condenser.
2) Tighten liquid line fitting to 18 ft. lbs. (24 N.m). To
complete installation, reverse removal procedure. Evacuate, charge,
and test system for proper operation.
Removal ("G", "L" & "M" Series)
1) Discharge A/C system, using approved recovery/recycling
equipment. Using a backup wrench, loosen evaporator inlet (liquid)
line fitting at evaporator. Disconnect inlet line. Remove and discard
"O" ring(s). Using Orifice Tube Remover/Installer (J-26549-E), remov\
e
orifice tube from liquid line.
2) If difficulty is encountered during removal of a plugged
or restricted orifice tube, remove as much residue as possible. Using
a heat gun, carefully apply heat 1/4" from dimples on liquid line. Be
careful not to overheat line.

3) If A/C pressure switch is located near orifice tube,
remove switch to protect it from heat. While heat is being applied,
grip orifice tube using orifice tube remover/installer. Use a turning
motion along with a push-pull motion to loosen and remove orifice
tube.
Installation
1) Clean liquid line fitting with refrigerant oil. Add one
ounce of refrigerant oil to system. Coat inside of liquid line and "O"
rings with refrigerant oil. Lubricate orifice tube and "O" ring with
refrigerant oil and insert them into liquid line. Insert shorter
orifice tube screen into liquid line first with long screen (inlet
end) toward condenser.
2) Tighten liquid line fitting to 20 ft. lbs. (27 N.m). To
complete installation, reverse removal procedure. Evacuate, charge,
and test system for proper operation.
Removal ("U" Series)
1) Remove air cleaner and duct assembly. Discharge A/C
system, using approved recovery/recycling equipment. Using a backup
wrench, loosen condenser outlet (liquid) line fitting at orifice tube.\
Disconnect liquid line. Remove and discard "O" rings. Using needle-
nose pliers, remove orifice tube from liquid line.
2) If difficulty is encountered during removal of a plugged
or restricted orifice tube, remove as much residue as possible. Using
a heat gun, carefully apply heat 1/4" from dimples on liquid line. Be
careful not to overheat line.
3) If A/C pressure switch is located near orifice tube,
remove switch to protect it from heat. While heat is being applied,
grip orifice tube using needle-nose pliers. Use a turning motion along
with a push-pull motion to loosen and remove orifice tube.
Installation
1) Clean liquid line fitting with refrigerant oil. Add one
ounce of refrigerant oil to system. Coat inside of liquid line and "O"
rings with refrigerant oil. Lubricate orifice tube and "O" ring with
refrigerant oil and insert them into liquid line. Insert orifice tube
into liquid line with long screen (inlet end) toward condenser.
2) Tighten liquid line fitting to 20 ft. lbs. (27 N.m). To
complete installation, reverse removal procedure. Evacuate, charge,
and test system for proper operation.
ORIFICE TUBE LOCATION & REMOVER/INSTALLER APPLICATION









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Application Orifice Tube Orifice Tube
Location Remover/Installer
Cars
"C" Body ...................... ( 1) .................. J-26549-D
"E" & "K" Body ................ ( 1) .................. J-26549-D
"F" Body .............. Evaporator Inlet .. ....................
"G" Body .............. Evaporator Inlet ............. J-26549-E
"H" Body .............. Condenser Outlet ............. J-26549-D
"J" Body .............. Condenser Outlet ............. J-26549-E
"N" Body ( 2) .......... Condenser Outlet ............. J-26549-E
"W" Body ...................... ( 3) .................. J-26549-E
Trucks & Vans
"C" & "K" Series
With Rear A/C ........ Evaporator Inlet ............. J-26549-E
Without Rear A/C ..... Condenser Outlet ............. J-26549-E
"G" Series ............ Evaporator Inlet ............. J-26549-E
"L" & "M" Series ...... Evaporator Inlet ............. J-26549-E
"S" & "T" Series ...... Evaporator Inlet ............. J-26549-D

"U" Series ............ Condenser Outlet ................... N/A
(1) - In evaporator (liquid) inlet line, between service valves, above
accumulator.
( 2) - Cutlass and Malibu only.
( 3) - In evaporator (liquid) inlet line, between high-side service
valve and evaporator.









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JEEP
NOTE: On Cherokee and Grand Cherokee, fixed orifice tube is located
in the liquid line. If the fixed orifice tube is faulty or
plugged, the liquid line and orifice tube must be replaced as
an assembly.
Removal & Installation (Cherokee & Grand Cherokee)
Disconnect battery negative cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
liquid line retaining clips. Disconnect liquid line from evaporator
inlet and condenser outlet tubes. Cover open refrigerant fittings to
protect from moisture and dirt. 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.
Removal & Installation (Wrangler)
1) Disconnect battery negative 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 needle nose pliers, remove fixed orifice tube from
condenser outlet tube. Note fixed orifice tube orientation for correct
installation. 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.
REFRIGERANT RECOVERY/RECYCLING
Refrigerant recovery/recycling equipment is used to remove
refrigerant from vehicle's A/C system without polluting atmosphere. To
remove and recycle refrigerant, ALWAYS follow instructions provided
with the refrigerant recovery/recycling equipment being used.
The removed refrigerant is filtered, dried and stored in a
tank within the recovery/recycling equipment until it is ready to be
pumped back into the vehicle's A/C system.
NOTE: Separate sets of hoses, manifold gauge set and refrigerant
recovery/recycling equipment MUST be used for R-12 and R-134a
systems. DO NOT mix R-12 and R-134a refrigerants, as their
refrigerant oils and desiccants are NOT compatible.
CHRYSLER CORP.
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.
FORD MOTOR CO.
1) Connect hoses from Recovery/Recycling/Charging Center
(023-00150) to high-side and low-side service valves. See SERVICE

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









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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

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