Dodge Dakota (R1). Manual — part 801
SERVICE CAUTIONS
CAUTION: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions supplied
with the service equipment being used.
Never add R-12 to a refrigerant system designed to
use R-134a. Damage to the system will result.
R-12 refrigerant oil must not be mixed with R-134a
refrigerant oil. They are not compatible.
Do not use R-12 equipment or parts on the R-134a
system. Damage to the system will result.
Do not overcharge the refrigerant system. This will
cause excessive compressor head pressure and
can cause noise and system failure.
Recover the refrigerant before opening any fitting
or connection. Open the fittings with caution, even
after the system has been discharged. Never open
or loosen a connection before recovering the refrig-
erant.
Do not remove the secondary retention clip from
any spring-lock coupler connection while the refrig-
erant system is under pressure. Recover the refrig-
erant before removing the secondary retention clip.
Open the fittings with caution, even after the sys-
tem has been discharged. Never open or loosen a
connection before recovering the refrigerant.
The refrigerant system must always be evacuated
before charging.
Do not open the refrigerant system or uncap a
replacement component until you are ready to ser-
vice the system. This will prevent contamination in
the system.
Before disconnecting a component, clean the out-
side of the fittings thoroughly to prevent contami-
nation from entering the refrigerant system.
Immediately after disconnecting a component from
the refrigerant system, seal the open fittings with a
cap or plug.
Before
connecting
an
open
refrigerant
fitting,
always install a new seal or gasket. Coat the fitting
and seal with clean refrigerant oil before connect-
ing.
Do not remove the sealing caps from a replacement
component until it is to be installed.
When installing a refrigerant line, avoid sharp
bends that may restrict refrigerant flow. Position the
refrigerant lines away from exhaust system compo-
nents or any sharp edges, which may damage the
line.
Tighten refrigerant fittings only to the specified
torque. The aluminum fittings used in the refriger-
ant system will not tolerate overtightening.
When disconnecting a refrigerant fitting, use a
wrench on both halves of the fitting. This will pre-
vent twisting of the refrigerant lines or tubes.
Refrigerant oil will absorb moisture from the atmo-
sphere if left uncapped. Do not open a container of
refrigerant oil until you are ready to use it. Replace
the cap on the oil container immediately after using.
Store refrigerant oil only in a clean, airtight, and
moisture-free container.
Keep service tools and the work area clean. Con-
tamination of the refrigerant system through care-
less work habits must be avoided.
24a - 2
HEATING & AIR CONDITIONING
R1
HEATING & AIR CONDITIONING (Continued)
SPECIFICATIONS
A/C APPLICATION TABLE
Item
Description
Notes
VEHICLE
R1 Dakota
SYSTEM
R134a w/ fixed
orifice tube
COMPRESSOR
Nippondenso
10PA17
ND - 8 PAG oil
Freeze–up
Control
2-wire
evaporator
temperature
sensor
Loss of
refrigerent
charge
a/c low
pressure switch
opens < 7-13
psi - resets >
15-25 psi
Accumulator
mounted
Pressure
transducer
460 psi
(cut-out) 290
psi (cut-in)
Liquid line
mounted
CONTROL
HEAD
manual type
and electric
Mode Door
electric
Blend Air Door
electric
Fresh/Recirc
door
electric
Blower Motor
hardwired to
control head
9
Credit card
9
resistor block
COOLING FAN
V-6 & V-8
electrical/
mechanial
cooling fan
mocule, I-4
(2.5)electric fan
Relay
Clutch
Electro-
mechanical
Control
relay
PCM
Draw
2.0 - 3.9 amps
@ 12 V
± 0.5V @ 70° F
Gap
0.016
9
- 0.031
9
DRB-III
Reads
TPS, RPM, A/C
transducer
pressure
Actuators
clutch relay (fan
relay 2.5 only),
actuator doors
TORQUE
DESCRIPTION . . . . . . . . . . . . . . . . . . . TORQUE
Compressor Mounting Bolts . . . . 41 N·m (30 ft. lbs.)
Intermediate Shaft Coupler Pinch Bolt . . . 13.5 N·m
(120 in. lbs.)
H-block Retaining Bolts . . . . . . 18 N·m (159 in. lbs.)
Refrigerant Lines at Compressor . . . . . . . . . 23 N·m
(17 ft. lbs.)
Refrigerant Lines at Accumulator . . . . . . . . 33 N·m
(25 ft. lbs.)
Condenser Mounting Bolts . . . 10.7 N·m (95 in. lbs.)
Refrigerant Line Support Bracket . . . . . . . . 22 N·m
(196 in. lbs.)
Low Pressure Cycling Switch . . Hand Tighten Only
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HEATING & AIR CONDITIONING
24a - 3
HEATING & AIR CONDITIONING (Continued)
A/C COMPRESSOR - 2.5L DIESEL
TABLE OF CONTENTS
page
page
A/C COMPRESSOR - 2.5L DIESEL
COMPRESSOR - 2.5L DIESEL . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
A/C COMPRESSOR - 2.5L
DIESEL
DESCRIPTION - COMPRESSOR DRIVE SYSTEM
Vehicles equipped with the 2.5L Turbo Diesel
Engine utilize a unique A/C Compressor Drive Sys-
tem. This system uses the belt driven, engine block
mounted power steering pump to drive the A/C com-
pressor (Fig. 1). This is made possible by positioning
the compressor directly behind the power steering
pump and using the pump shaft to drive the A/C
compressor and clutch assembly via a coupler and
H-block (Fig. 1). The 2.5L power steering pump cen-
ter shaft protrudes from the front and rear of the
pump assembly. The front portion of the shaft is used
for drive pulley attachment, the rear is used for cou-
pler attachment. Lip-ring seals are located at each
end of the center shaft to prevent fluid leakage. The
coupler is held on the power steering pump shaft via
a pinch bolt. The H-block is held on the coupler via
two 13mm hex bolts (Fig. 2). An A/C compressor
drive cup is used to allow the H-block to bolt directly
to the compressor clutch, thus driving the A/C com-
pressor (Fig. 2). The compressor drive cup threads
(right-hand) on to the compressor clutch assembly
(Fig. 2).
DIAGNOSIS AND TESTING - COMPRESSOR -
2.5L DIESEL
Refer to the Diesel A/C Application Table when
diagnosing the A/C system on a vehicle equipped
with the 2.5L diesel engine.
Refer to the AN service manual for a complete list
of climate control system diagnosis and testing proce-
dures.
Refer to Wiring Diagrams for service information
and circuit diagrams for the diesel climate control
system components.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Recover the refrigerant from the refrigerant
system(Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT
-
STANDARD
PROCEDURE).
Fig. 1 Compressor Drive System
Fig. 2 Diesel Compressor Assembly
24a - 4
A/C COMPRESSOR - 2.5L DIESEL
R1
(3) Raise and support the vehicle on the hoist
(4) Remove the (2) refrigerant line retaining bolts
from the compressor (Fig. 3). Remove both lines from
the compressor and cover all openings.
(5) Disconnect the compressor clutch electrical con-
nector (Fig. 3).
(6) Loosen the H–Block intermediate shaft coupler
pinch bolt (Fig. 4).
(7) Rotate the H–Block to access and remove the
(2) H–Block retaining bolts threading into the com-
pressor drive cup (Fig. 4).
(8) Remove the compressor mounting bolts, (4)
spacers and compressor from the vehicle (Fig. 3).
(9) If necessary, unscrew the A/C drive cup and
transfer to the new compressor.
INSTALLATION
NOTE:
If
a
replacement
compressor
is
being
installed, be certain to check the refrigerant oil
level. See Refrigerant Oil Level in the Service Pro-
cedures section of the AN service manual.
NOTE: Compressor installation requires (4) spacers
located between the engine block and the compres-
sor body to properly position the compressor. The
spacers containing a dowel pin are used in the
front (front of engine) mounting location while the
undoweled are used in the rear.
Fig. 3 Compressor Position & Orientation
1 - COMPRESSOR ELECTRICAL CONNECTOR
2 - REFRIGERANT LINE RETAINING BOLTS
3 - COMPRESSOR RETAINING BOLTS
4 - H-BLOCK
Fig. 4 Compressor Drive Assembly
1 - COMPRESSOR DRIVE CUP RETAINING BOLTS
(COMPRESSOR REMOVED)
2 - H-BLOCK ASSEMBLY
3 - INTERMEDIATE SHAFT COUPLER PINCH BOLT
Fig. 5 Compressor Position & Orientation
1 - COMPRESSOR ELECTRICAL CONNECTOR
2 - REFRIGERANT LINE RETAINING BOLTS
3 - COMPRESSOR RETAINING BOLTS
4 - H-BLOCK
R1
A/C COMPRESSOR - 2.5L DIESEL
24a - 5
A/C COMPRESSOR - 2.5L DIESEL (Continued)
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