1999 DODGE RAM belt

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.

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.

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.


* A /C -H EA TE R S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
A/C-Heater System Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Heating, Ventilation and Air Conditioning
ACCUMULATORS
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
AIR CONDITIONING FITTINGS
AIR CONDITIONING HOSES
AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES
AIR CONTROL DOORS
AIR DAMS (EXTERNAL)
AIR DISTRIBUTION SYSTEM
BELTS
BLEND DOORS
BLOWER FANS (BLOWER WHEEL OR SQUIRREL CAGE)
BLOWER MOTORS
BLOWER RESISTORS
BLOWER SWITCHES
CABIN AIR FILTERS
CIRCUIT BREAKERS
COMPRESSOR CLUTCH ASSEMBLIES
COMPRESSORS
CONDENSER AIR SEALS
CONDENSER FAN MOTORS
CONDENSERS
CONNECTORS
CONTROL CABLES
CONTROL HEADS (FUNCTION SELECTORS)
CONTROL LINKAGES
CONTROL MODULES
COOLANT
COOLING FAN BLADES
COOLING FAN CLUTCHES
COOLING FAN MOTORS
EVAPORATOR DRAIN TUBES
EVAPORATOR PRESSURE REGULATORS (EPRS)
EVAPORATORS
EXPANSION VALVES
FUNCTION SELECTORS
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSIBLE LINKS
GASKETS
HEATER CASES
HEATER CONTROL VALVES
HEATER CORES

Application incorrect,
affecting air
conditioning
system performance ..... A .. Require repair or replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Bent, affecting air
conditioning system
performance ............ A .. Require repair or replacement.
Blocked, affecting air
conditioning system
performance ............ A .. Require repair or replacement.
Broken, affecting air
conditioning system
performance ............ A .. Require repair or replacement.
Cracked, affecting air
conditioning system
performance ............ A .. Require repair or replacement.
Loose, affecting air
conditioning system
performance ............ A ................. Require repair.
Loose, not affecting air
conditioning system
performance ............ 2 ................. Suggest repair.
Missing, affecting air
conditioning system
performance ............ C ............ Require replacement.









\









\









\









\









\









\









\


AIR DISTRIBUTION SYSTEM
See PLENUMS.
BELTS
BELT INSPECTION








\









\









\









\









\









\









\


Condition Code Procedure
Alignment incorrect ..... B .......... ( 1) Further inspection
required.
Cracked ................. 1 ............ Suggest replacement.
Frayed .................. 1 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .......... ( 2) Further inspection
required.
Plies separated ......... A ............ Require replacement.
Serpentine belt routed
incorrectly ............ B ................. Require repair.
Tension out of
specification .......... B ........... Require adjustment or
replacement.
Worn beyond
adjustment range ....... B ............ Require replacement.

functioning ............ A ... Require repair or replacement
of hardware.
Bearing noisy ........... 2 ............ Suggest replacement.
Bearing seized .......... A .. Require repair or replacement.
Bearing worn ............ 1 ............ Suggest replacement.
Cracked ................. A ............ Require replacement.
Loose ................... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Pulley damaged, affecting
belt life .............. A ............ Require replacement.









\









\









\









\









\









\









\


RADIATORS
RADIATOR INSPECTION








\









\









\









\









\









\









\


Condition Code Procedure
Air flow obstruction .... A ................. Require repair.
Application incorrect ... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A .. Require repair or replacement
of hardware.
Connection leaking ...... A .. Require repair or replacement.
Corroded ................ 1 .. Suggest repair or replacement.
Drain inoperative ....... A .. Require repair or replacement.
Fins damaged, affecting
performance ............ A .. Require repair or replacement.
Fins damaged, not
affecting performance .. .. ........ No service suggested or
required.
Internal oil cooler
leaking ................ A .. Require repair or replacement.
Internal restrictions ... B .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A .. Require repair or replacement.
Tubes damaged, affecting
performance ............ A .. Require repair or replacement.
Tubes damaged, not
affecting performance .. .. ........ No service suggested or
required.









\









\









\









\









\









\









\


RECEIVER-DRIERS
NOTE: For VIRs, see VALVES IN RECEIVER (VIRS) .
RECEIVER-DRIER INSPECTION









\









\









\









\









\









\









\


Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware

Alignment incorrect ..... B .. Require repair or replacement.
Application incorrect ... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Bearing worn ............ 1 ............ Suggest replacement.
Belt tension incorrect .. B ... Require adjustment or repair.
Bracket cracked ......... A .. Require repair or replacement.
Housing cracked ......... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 ............ Suggest replacement.
Pulley damaged, affecting
belt life .............. A ............ Require replacement.
Seized .................. A .. Require repair or replacement.









\









\









\









\









\









\









\


THERMISTORS AND PRESSURE SENSORS
NOTE: Includes, but not limited to, In-Car Temperature, Ambient
Air Temperature, Sun Load Sensor, etc.
THERMISTOR AND PRESSURE SENSOR INSPECTION









\









\









\









\









\









\









\


Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Calibration incorrect ... B .. Require repair or replacement.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted,
affecting performance .. A ........... ( 1) Require repair or
replacement.
Connector melted, not
affecting performance .. 2 ........... ( 1) Suggest repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........... ( 2) Require repair or
replacement.
Missing ................. C ............ Require replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance ... 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.