Dodge Dakota (R1). Manual - part 800

The R-134a refrigerant system charge capacity for

this vehicle is: 0.907 kilograms (32 ounces).

REFRIGERANT OIL

DESCRIPTION

The refrigerant oil used in R-134a refrigerant sys-

tems is a synthetic-based, PolyAlkylene Glycol (PAG),
wax-free lubricant. Mineral-based R-12 refrigerant
oils are not compatible with PAG oils, and should
never be introduced to an R-134a refrigerant system.

There are different PAG oils available, and each

contains a different additive package. The SD7H15
compressor used in this vehicle is designed to use an
SP-20 PAG refrigerant oil. Use only refrigerant oil of
this same type to service the refrigerant system.

OPERATION

After performing any refrigerant recovery or recy-

cling operation, always replenish the refrigerant sys-
tem with the same amount of the recommended
refrigerant oil as was removed. Too little refrigerant
oil can cause compressor damage, and too much can
reduce air conditioning system performance.

PAG refrigerant oil is much more hygroscopic than

mineral oil, and will absorb any moisture it comes
into contact with, even moisture in the air. The PAG
oil container should always be kept tightly capped
until it is ready to be used. After use, recap the oil
container immediately to prevent moisture contami-
nation.

STANDARD PROCEDURE - REFRIGERANT OIL
LEVEL

When an air conditioning system is assembled at

the factory, all components except the compressor are
refrigerant oil free. After the refrigerant system has
been charged and operated, the refrigerant oil in the
compressor is dispersed throughout the refrigerant
system. The accumulator, evaporator, condenser, and
compressor will each retain a significant amount of
the needed refrigerant oil.

It is important to have the correct amount of oil in

the refrigerant system. This ensures proper lubrica-
tion of the compressor. Too little oil will result in
damage to the compressor. Too much oil will reduce
the cooling capacity of the air conditioning system.

It will not be necessary to check the oil level in the

compressor or to add oil, unless there has been an oil
loss. An oil loss may occur due to a rupture or leak
from a refrigerant line, a connector fitting, a compo-
nent, or a component seal. If a leak occurs, add 30
milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system after the repair has been made.
Refrigerant oil loss will be evident at the leak point

by the presence of a wet, shiny surface around the
leak.

Refrigerant oil must be added when a accumulator,

evaporator coil, or condenser are replaced. See the
Refrigerant Oil Capacities chart. When a compressor
is replaced, the refrigerant oil must be drained from
the old compressor and measured. Drain all of the
refrigerant oil from the new compressor, then fill the
new compressor with the same amount of refrigerant
oil that was drained out of the old compressor.

Refrigerant Oil Capacities

Component

fl oz

A/C System

210

7.1

Accumulator

Condenser

Evaporator

Compressor

drain and measure
the oil from the old
compressor as noted

SUCTION LINE

REMOVAL

Any kinks or sharp bends in the refrigerant plumb-

ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.

High pressures are produced in the refrigerant sys-

tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.

WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) AND (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION) BEFORE PERFORMING THE FOLLOWING
OPERATION.

(1) Disconnect and isolate the battery negative

cable.

(2) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT

STANDARD

PROCEDURE).

24 - 46

PLUMBING

REFRIGERANT (Continued)

(3) Unplug the wire harness connector from the a/c

pressure transducer switch.

(4) Remove the fasteners and disconnect the refrig-

erant line couplers at the condenser and the accumu-
lator

(Refer

HEATING

AIR

CONDITIONING/PLUMBING - REMOVAL). Install
plugs in, or tape over all of the opened refrigerant
line fittings.

(5) Remove the fastener that secures the refriger-

ant line support bracket near the compressor.

(6) Remove the screw that secures the refrigerant

line manifold to the compressor. Install plugs in, or
tape over all of the opened refrigerant line fittings.

(7) Remove the suction and discharge line assem-

bly from the vehicle.

INSTALLATION

Any kinks or sharp bends in the refrigerant plumb-

High pressures are produced in the refrigerant sys-

WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) AND (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION) BEFORE PERFORMING THE FOLLOWING
OPERATION.

(1) Remove the tape or plugs from all of the refrig-

erant line fittings. Install the refrigerant line cou-
plers to the condenser and the accumulator (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- INSTALLATION). Tighten the fasteners to 22 ±3.38
N·m (200 ±30 in. lbs.).

(2) Install the refrigerant line manifold to the com-

pressor. Tighten the mounting screw to 22 N·m (200
in. lbs.).

(3) Install the fastener that secures the refrigerant

line support bracket near the compressor. Tighten
the mounting screw to 6.77 ±1.7 N·m (60 ±15 in.
lbs.).

(4) Plug in the wire harness connector to the pres-

sure transducer switch.

(5) Connect the battery negative cable.

(6) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE).

(7) Charge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE).

REFRIGERANT LINE COUPLER

DESCRIPTION- REFRIGERANT LINE COUPLERS

Spring-lock type refrigerant line couplers are used

to connect many of the refrigerant lines and other
components to the refrigerant system. These couplers
require a special tool for disengaging the two coupler
halves.

OPERATION- REFRIGERANT LINE COUPLERS

The spring-lock coupler is held together by a garter

spring inside a circular cage on the male half of the
fitting (Fig. 7). When the two coupler halves are con-
nected, the flared end of the female fitting slips
behind the garter spring inside the cage on the male
fitting. The garter spring and cage prevent the flared
end of the female fitting from pulling out of the cage.

Two O-rings on the male half of the fitting are

used to seal the connection. These O-rings are com-
patible with R-134a refrigerant and must be replaced
with O-rings made of the same material.

Fig. 7 Spring-Lock Coupler - Typical

1 - MALE HALF SPRING-LOCK COUPLER
2 - FEMALE HALF SPRING-LOCK COUPLER
3 - SECONDARY CLIP
4 - CONNECTION INDICATOR RING
5 - COUPLER CAGE
6 - GARTER SPRING
7 - COUPLER CAGE
8 - “O” RINGS

PLUMBING

24 - 47

SUCTION LINE (Continued)

Secondary clips are installed over the two con-

nected coupler halves at the factory for added blowoff
protection.

REMOVAL

WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION) BEFORE PERFORMING THE FOLLOWING
OPERATION.

(1) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT

STANDARD

PROCEDURE).

(2) Remove the secondary clip from the spring-lock

coupler.

(3) Fit the proper size A/C line disconnect tool

(Special Tool Kit 7193) over the spring-lock coupler
cage (Fig. 8).

(4) Close the two halves of the A/C line disconnect

tool around the spring-lock coupler.

(5) Push the A/C line disconnect tool into the open

side of the coupler cage to expand the garter spring.
Once the garter spring is expanded and while still
pushing the disconnect tool into the open side of the
coupler cage, pull on the refrigerant line attached to
the female half of the coupler fitting until the flange
on the female fitting is separated from the garter

spring and cage on the male fitting within the dis-
connect tool.

NOTE: The garter spring may not release if the A/C
line disconnect tool is cocked while pushing it into
the coupler cage opening.

(6) Open and remove the A/C line disconnect tool

from the disconnected spring-lock coupler.

(7) Complete the separation of the two halves of

the coupler fitting.

INSTALLATION

WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) AND (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION) BEFORE PERFORMING THE FOLLOWING
OPERATION.

(1) Check to ensure that the garter spring is

located within the cage of the male coupler fitting,
and that the garter spring is not damaged.

(a) If the garter spring is missing, install a new

spring by pushing it into the coupler cage opening.

(b) If the garter spring is damaged, remove it

from the coupler cage with a small wire hook (DO
NOT use a screwdriver) and install a new garter
spring.
(2) Clean any dirt or foreign material from both

halves of the coupler fitting.

(3) Install new O-rings on the male half of the cou-

pler fitting.

CAUTION: Use only the specified O-rings as they
are made of a special material for the R-134a sys-
tem. The use of any other O-rings may allow the
connection to leak intermittently during vehicle
operation.

(4) Lubricate the male fitting and O-rings, and the

inside of the female fitting with clean R-134a refrig-
erant oil. Use only refrigerant oil of the type recom-
mended for the compressor in the vehicle.

(5) Fit the female half of the coupler fitting over

the male half of the fitting.

(6) Push together firmly on the two halves of the

coupler fitting until the garter spring in the cage on
the male half of the fitting snaps over the flanged
end on the female half of the fitting.

(7) Ensure that the spring-lock coupler is fully

engaged by trying to separate the two coupler halves.
This is done by pulling the refrigerant lines on either
side of the coupler away from each other.

(8) Reinstall the secondary clip over the spring-

lock coupler cage.

Fig. 8 Refrigerant Line Spring-Lock Coupler

Disconnect

24 - 48

PLUMBING

REFRIGERANT LINE COUPLER (Continued)

HEATING & AIR CONDITIONING

TABLE OF CONTENTS

page

HEATING & AIR CONDITIONING

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3

A/C COMPRESSOR - 2.5L DIESEL

. . . . . . . . . . . . 4

A/C CONDENSER - 2.5L DIESEL . . . . . . . . . . . . . . 7
ACCUMULATOR

. . . . . . . . . . . . . . . . . . . . . . . . . . 9

A/C DISCHARGE LINE

. . . . . . . . . . . . . . . . . . . . . 11

LIQUID LINE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

HEATING & AIR
CONDITIONING

DESCRIPTION - HVAC SYSTEM 2.5 DIESEL

The heating and air conditioning system on diesel

engine equipped vehicles contains the same compo-
nents as gas engine equipped vehicles. Refer to the
AN service manual for description and operation of
all heating and air conditioning system components.

SERVICE WARNINGS

WARNING: THE AIR CONDITIONING SYSTEM CON-
TAINS REFRIGERANT UNDER HIGH PRESSURE.
SEVERE PERSONAL INJURY MAY RESULT FROM
IMPROPER

SERVICE

PROCEDURES.

REPAIRS

SHOULD ONLY BE PERFORMED BY QUALIFIED
SERVICE PERSONNEL.
AVOID

BREATHING

THE

REFRIGERANT

AND

REFRIGERANT OIL VAPOR OR MIST. EXPOSURE
MAY IRRITATE THE EYES, NOSE, AND/OR THROAT.
WEAR EYE PROTECTION WHEN SERVICING THE
AIR CONDITIONING REFRIGERANT SYSTEM. SERI-
OUS EYE INJURY CAN RESULT FROM DIRECT
CONTACT WITH THE REFRIGERANT. IF EYE CON-
TACT OCCURS, SEEK MEDICAL ATTENTION IMME-
DIATELY.

DO NOT EXPOSE THE REFRIGERANT TO OPEN
FLAME. POISONOUS GAS IS CREATED WHEN
REFRIGERANT IS BURNED. AN ELECTRONIC LEAK
DETECTOR IS RECOMMENDED.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE THE WORK AREA BEFORE RESUMING
SERVICE. LARGE AMOUNTS OF REFRIGERANT
RELEASED IN A CLOSED WORK AREA WILL DIS-
PLACE THE OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF R-134a REFRIGER-
ANT AT AVERAGE TEMPERATURE AND ALTITUDE
IS EXTREMELY HIGH. AS A RESULT, ANYTHING
THAT COMES IN CONTACT WITH THE REFRIGER-
ANT WILL FREEZE. ALWAYS PROTECT THE SKIN
OR DELICATE OBJECTS FROM DIRECT CONTACT
WITH THE REFRIGERANT.
THE R-134a SERVICE EQUIPMENT OR THE VEHI-
CLE REFRIGERANT SYSTEM SHOULD NOT BE
PRESSURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR. SOME MIXTURES OF AIR AND
R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE
AT ELEVATED PRESSURES. THESE MIXTURES ARE
POTENTIALLY DANGEROUS, AND MAY RESULT IN
FIRE OR EXPLOSION CAUSING INJURY OR PROP-
ERTY DAMAGE.

HEATING & AIR CONDITIONING

24a - 1

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