New Halla HS18 - 8 Groove Clutch Assembly - 4.75" Pulley Diameter, .85" Gauge Line - 4 Boss Direct Mount
2006 and later Dodge Trucks have a Totally Integrated Power Module, TIPM. This module is used instead of a fuse box, and there is no relay controlling the A/C as in previous generations. This TIPM has been very problematic for Dodge, particularly with the 5.9 Diesel trucks. The TIPM controls not only the air conditioning, but also brakes, lights, and various other items. There are several flashes and updates available from the dealer for this module. If the vehicle is experiencing erratic or no A/C clutch engagement, it is necessary to examine the TIPM. Keep in mind, the clutch coil on this compressor has an embedded diode which also commonly fails, many times in conjunction with the TIPM, so don't forget to test resistance.
Compressor removal and installation time is .8 hours, not including evacuate and recharge.
5.9L/6.7L DIESEL ENGINES
WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow these instructions may result in possible serious or fatal injury.
NOTE: The A/C compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch, clutch coil or engine.
1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system.
3. Remove the accessory drive belt. See Below.
4. Remove the bolt (1) that secures the A/C suction and discharge line assembly (2) to the A/C compressor (3).
5. Disconnect the refrigerant line assembly from the A/C compressor and remove and discard the O-ring seals and gasket.
6. Install plugs in, or tape over all of the opened refrigerant line fittings and compressor ports.
7. Disconnect the wire harness from the clutch field coil wire lead connector (4).
8. Remove the four bolts (1) that secure the A/C compressor (2) to the mounting bracket (3) located on the right side of the cylinder block (4).
9. Remove the A/C compressor from the engine compartment.
Installation
CAUTION: If the A/C compressor is being replaced, be certain to adjust the refrigerant system oil level. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. (this compressor contains a full charge of oil)
CAUTION: The A/C accumulator must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C accumulator can cause serious damage to the replacement A/C compressor.
NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be removed from the new A/C compressor.
NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.
1. If the A/C compressor (2) is being replaced, the refrigerant oil in the old compressor must be first drained and measured. Then the oil in the new A/C compressor must be drained. Finally, the new compressor must be refilled with the same amount of new refrigerant oil that was drained out of the old compressor. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. (this compressor comes with a full charge of oil)
2. Position the A/C compressor onto the mounting bracket (3) located on the right side of the cylinder block (4).
3. Install and hand tighten the four bolts (1) that secure the A/C compressor to the mounting bracket.
4. Tighten the bolts that secure the A/C compressor to the mounting bracket to 27 N·m (20 ft. lbs.).
5. Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.
6. Lubricate new O-ring seals with clean refrigerant oil and install them and a new gasket onto the refrigerant line fittings. Use only the specified O-ring seals as they are 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.
7. Install the A/C suction and discharge line assembly (2) onto the A/C compressor (3).
8. Install the bolt (1) that secures the refrigerant line assembly to the A/C compressor. Tighten the bolt to 23 N·m (17 ft. lbs.).
9. Connect the wire harness to the clutch field coil wire lead connector (4).
10. Install the accessory drive belt. See Below.
11. Reconnect the negative battery cable.
12. Evacuate the refrigerant system.
13. Charge the refrigerant system.
Belt Removal & Installation
Removal
1. A 1/2 inch square hole is provided in the automatic belt tensioner. Attach a suitable tool into this hole.
2. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt.
3. Remove belt from water pump pulley first.
4. Remove belt from vehicle.
Installation
CAUTION: When installing the accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction.
1. Position drive belt over all pulleys except water pump pulley.
2. Attach a suitable tool to the accessory drive belt tensioner.
3. Rotate accessory drive belt tensioner clockwise. Place belt over water pump pulley. Let tensioner rotate back into place. Remove tool. Be sure belt is properly seated on all pulleys.
The
Accumulator or
Filter Drier should always be replaced when the Air Conditioning System is opened. (
see why) The
Orifice Tube, if equipped, should always be replaced and the
Expansion Valve, if equipped, should at least be inspected for proper operation if not replaced. (
see why)