Dodge Ram Truck 1500-2500-3500. Manual — part 2072

4. Remove the tape or plugs from the opened refrig-

erant line fittings and the compressor ports.

5. Lubricate new seals with clean refrigerant oil and

install them onto the refrigerant line fittings. Use
only the specified seals as they are made of a spe-
cial material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.

6. Install the A/C suction line (1) and the A/C dis-

charge line (3) onto the A/C compressor (2).

7. Install the bolts (5) that secure the refrigerant lines

to the A/C compressor. Tighten the bolts to 20 N·m
(15 ft. lbs.).

8. Connect the wire harness connector to the A/C

compressor clutch coil connector (4).

9. Install the serpentine drive belt (Refer to 7 - COOL-

ING/ACCESSORY DRIVE/BELTS-DRIVE - INSTAL-
LATION).

10. Reconnect the negative battery cable.

11. Evacuate the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD

PROCEDURE - REFRIGERANT SYSTEM EVACUATE).

12. Charge the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-

CEDURE - REFRIGERANT SYSTEM CHARGE).

CONDENSER-A/C

DESCRIPTION

The A/C condenser is located in the front of the engine compartment behind the grille. The A/C condenser is a heat
exchanger that allows the high-pressure refrigerant gas being discharged by the A/C compressor to give up its heat
to the air passing over the condenser fins, which causes the refrigerant to cool and change to a liquid state.

OPERATION

When air passes through the fins of the A/C condenser, the high-pressure refrigerant gas within the A/C condenser
gives up its heat. The refrigerant then condenses as it leaves the A/C condenser and becomes a high-pressure
liquid. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the A/C
system. Therefore, it is important that there are no objects placed in front of the radiator grille openings at the front
of the vehicle or foreign material on the condenser fins that might obstruct proper air flow. Also, any factory-installed
air seals or shrouds must be properly reinstalled following radiator or A/C condenser service.

The A/C condenser cannot be repaired and, if faulty or damaged, it must be replaced.

REMOVAL

3.7L/4.7L/5.7L ENGINES

WARNING: Refer to the applicable warnings and cautions for this system before performing the following
operation (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS). Failure to follow the warnings and cautions could result
in possible personal injury or death.

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PLUMBING

DR/DH

1. Recover the refrigerant from the refrigerant system

(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING

-

STANDARD

PROCEDURE

-

REFRIGERANT SYSTEM RECOVERY).

2. Disconnect and isolate the negative battery cable.

3. Disconnect the A/C discharge line and the A/C liq-

uid line from the A/C condenser (Refer to 24 -
HEATING

&

AIR

CONDITIONING/PLUMBING/

LINE-A/C LIQUID - REMOVAL) and (Refer to 24 -
HEATING

&

AIR

CONDITIONING/PLUMBING/

LINE-A/C DISCHARGE - REMOVAL).

4. Disconnect the wire harness connector (8) from the

A/C condenser cooling fan motor (7).

5. Remove the two bolts (1 and 9) that secure the

A/C condenser to the front upper crossmember (2).

6. Carefully lift the A/C condenser and cooling fan assembly to disconnect the lower mounting tabs (6) from the

lower mounting flanges (3) and remove the assembly from the engine compartment.

7. If required, place the A/C condenser and the cooling fan assembly on a workbench and remove the four screws

(4 and 5) that secure the cooling fan to the A/C condenser and separate the fan from the condenser.

5.9L DIESEL ENGINE

WARNING: Refer to the applicable warnings and cautions for this system before performing the following
operation (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS). Failure to follow the warnings and cautions could result
in possible personal injury or death.

1. Recover the refrigerant from the refrigerant system

(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING

-

STANDARD

PROCEDURE

-

REFRIGERANT SYSTEM RECOVERY).

2. Disconnect and isolate the negative battery cable.

3. Disconnect the A/C discharge line (1) and the A/C

liquid line (3) from the A/C condenser (5) (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
LINE-A/C LIQUID - REMOVAL) and (Refer to 24 -
HEATING

&

AIR

CONDITIONING/PLUMBING/

LINE-A/C DISCHARGE - REMOVAL).

4. Remove the four bolts (2, 4, 6 and 7) that secure

the A/C condenser to the charge air cooler.

5. Remove the A/C condenser from the engine

compartment.

DR/DH

PLUMBING

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8.3L ENGINE

WARNING: Refer to the applicable warnings and cautions for this system before performing the following
operation (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS). Failure to follow the warnings and cautions could result
in possible personal injury or death.

1. Recover the refrigerant from the refrigerant system

(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING

-

STANDARD

PROCEDURE

-

REFRIGERANT SYSTEM RECOVERY).

2. Disconnect and isolate the negative battery cable.

3. Disconnect the A/C discharge line and the A/C liq-

uid line from the A/C condenser (Refer to 24 -
HEATING

&

AIR

CONDITIONING/PLUMBING/

LINE-A/C LIQUID - REMOVAL) and (Refer to 24 -
HEATING

&

AIR

CONDITIONING/PLUMBING/

LINE-A/C DISCHARGE - REMOVAL).

4. Remove the two bolts (1) that secure the A/C con-

denser and shroud assembly (4) to the upper radi-
ator support (2).

5. Carefully lift the A/C condenser and shroud assem-

bly off of the front bumper support (3) and remove
the assembly from the engine compartment.

6. If required, place the A/C condenser and shroud

assembly on a workbench and remove the six bolts
(3) that secure the condenser shroud (2) to the A/C
condenser (1) and separate the shroud from the
A/C condenser.

INSTALLATION

3.7L/4.7L/5.7L ENGINES

NOTE: If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrig-
erant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

24 - 290

PLUMBING

DR/DH

1. If removed, install the condenser cooling fan onto

the A/C condenser.

2. Install the four screws (4 and 5) that secure the

cooling fan to the A/C condenser. Tighten the
screws to 2.2 N·m (20 in. lbs.).

3. Position the A/C condenser and cooling fan assem-

bly into the engine compartment.

4. Install the lower mounting tabs (6) into the lower

mounting flanges (3).

5. Install the two bolts (1 and 9) that secure the A/C

condenser to the upper front crossmember (2).
Tighten the bolts to 10.5 N·m (95 in. lbs.).

6. Connect the wire harness connector (8) to the A/C

condenser cooling fan motor (7).

7. Connect the A/C discharge line and the A/C liquid

line onto the A/C condenser (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/LINE-A/C DISCHARGE
- INSTALLATION) and (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/LINE-A/C LIQUID - INSTAL-
LATION).

8. Reconnect the negative battery cable.

9. Evacuate the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-

CEDURE - REFRIGERANT SYSTEM EVACUATE).

10. Charge the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-

CEDURE - REFRIGERANT SYSTEM CHARGE).

5.9L DIESEL ENGINE

NOTE: If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrig-
erant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

1. Position the A/C condenser (5) into the engine

compartment.

2. Install the four bolts (2, 4, 6 and 7) that secure the

A/C condenser to the charge air cooler. Tighten the
bolts to 10.5 N·m (95 in. lbs.).

3. Remove the tape or plugs from the liquid line fitting

and condenser outlet port.

4. Lubricate a new rubber O-ring seal with clean

refrigerant oil and install it on the liquid line fitting.
Use only the specified O-ring as it is made of a
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.

5. Connect the A/C discharge line (1) and the A/C liq-

uid line (3) onto the A/C condenser (Refer to 24 -
HEATING

&

AIR

CONDITIONING/PLUMBING/

LINE-A/C

DISCHARGE

-

INSTALLATION)

and

(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/LINE-A/C LIQUID - INSTALLATION).

6. Reconnect the negative battery cable.

7. Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).

DR/DH

PLUMBING

24 - 291