battery DODGE RAM 1999 Service Repair Manual

"B" ABBREVIATION TABLE

"B" ABBREVIATION TABLE
ABBREVIATION DEFINITION B/P Backpressure BAC By-Pass Air Control BAP Barometric Absolute Pressure Sensor BARO Barometric BBDC Before Bottom Dead Center BCM Body Control Module BDC Bottom Dead Center BHP Brake Horsepower BLK Black BLU Blue BMAP Barometric & Manifold Absolute Pressure
Sensor BOO Brake On-Off Switch BP Barometric Pressure sensor BPS Barometric Pressure sensor BPT Backpressure Transducer BRN Brown BTDC Before Top Dead Center BTU British Thermal Unit BVSV Bimetallic Switching Valve Baro. Barometric Batt. Battery Bbl. Barrel (Example:4-Bbl.) Blst. Ballast Blwr. Blower Brkr. Breaker

"C" ABBREVIATION TABLE

"C" ABBREVIATION TABLE
ABBREVIATION DEFINITION C Celsius (Degrees) C(3) Computer Controlled Coil Ignition C(4) Computer Controlled Catalytic Converter CANP Canister Purge solenoid CARB California Air Resources Board CAT Catalytic Converter CB Circuit Breaker CBD Closed Bowl Distributor CBVV Carburetor Bowl Vent valve cc Cubic Centimeter CCC Computer Command Control CCD Computer Controlled Dwell CCM Central Control Module CCO Converter Clutch Override CCOT Cycling Clutch Orifice Tube CCW Counterclockwise CDI Capacitor Discharge Ignition CEC Computerized Engine Control CFI Central Fuel Injection CID Cubic Inch Displacement CID Cylinder Identification sensor CIS Continuous Injection System CIS-E Continuous Injection System-Electronic

"T" ABBREVIATION TABLE

"T" ABBREVIATION TABLE
ABBREVIATION DEFINITION T.V. Throttle Valve _ TAB Thermactor Air By-Pass _ TAC Thermostatic Air Cleaner _ TAD Thermactor Air Diverter _ TAN Tan _ TBI Throttle Body Injection _ TCC Torque Converter Clutch _ TCCS Toyota Computer Control System TDC Top Dead Center _ TDCL Total Diagnostic Communication TFI Thick Film Ignition system _ TGS Top Gear Switch (cancels SIL in THERMAC Thermostatic Air Cleaner _ THS Transmission Hydraulic Switch _ TP/TPS Throttle Position Sensor _ TPI Tuned Port Injection _ TPS Throttle Position Sensor/Switch TS Temperature Sensor _ TSB Technical Service Bulletin _ TTS Transmission Temperature Switch TV Thermovalve _ TWC Three-Way Catalyst _ Temp. Temperature _ Trans. Transaxle/Transmission _

"V" ABBREVIATION TABLE

"V" ABBREVIATION TABLE
ABBREVIATION DEFINITION V Valve _ VAF Vane Air Flow sensor or circuit _ VAPS Variable Assist Power Steering _ VAT Vane Air Temperature _ VATS Vehicle Anti-Theft System _ VBATT Vehicle Battery Voltage _ VCC Viscous Converter Clutch _ VIN Vehicle Identification Number _ VIO Violet _ VLR Volt Loop Reserve _ VM Vacuum Modulator _ VM Vane Meter _ VOM Volt-Ohmmeter (Analog) _ VPWR Vehicle Power supply voltage (10-14 VREF Voltage Reference (ECA supplied ref VRV Vacuum Regulator Valve _ VSC Vehicle Speed Control sensor or sign VSS Vehicle Speed Sensor or signal _ VSV Vacuum Switching Valve _ Vac. Vacuum _ Volt. Voltage _

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.

Installation (Cherokee & Wrangler)
1) Install clutch coil and clutch coil snap ring. Install
clutch coil wire harness to compressor housing. Align pulley and
bearing assembly on front compressor housing hub. Using Installer (C-
6871), press pulley and bearing assembly onto compressor housing hub.
Thread installer on compressor shaft and tighten nut until pulley
assembly is seated.
2) Install external front snap ring with beveled side facing
outward. Ensure snap ring is properly seated. Install compressor shaft
key and original shims. Using a plastic mallet and Driver (C-6463),
install clutch plate on compressor shaft. Tighten compressor shaft nut
to 10 ft. lbs. (14 N.m).
3) Using feeler gauge, measure air gap between clutch plate
and pulley assembly in several areas. Air gap should be 0.016-0.031"
(0.41-0.79 mm). If air gap is not within specification, adjust shim
thickness as necessary. If air gap is not consistent around clutch
plate, lightly pry up or tap down on clutch plate to make corrections.
To complete installation, reverse removal procedure.
Installation (Dakota, Durango & Ram Pickup)
1) Install clutch coil and clutch coil snap ring. Install
clutch coil wire harness to compressor housing. Align pulley and
bearing assembly on front compressor housing hub.
2) Install Handle (6464) and Driver (6143) into pulley
assembly bearing cavity. Ensure outer edge of driver rests firmly on
inner race of bearing. Using hammer, install pulley and bearing
assembly. While tapping on handle, guide pulley and bearing assembly
to prevent binding. Ensure pulley assembly bottoms against compressor
housing. Install external snap ring.
3) Install original shim(s) and compressor shaft key. Use a
hammer and Shaft Protector (6141-2) to install clutch plate on
compressor shaft. Ensure clutch plate bottoms out on clutch shims.
Replace compressor shaft nut and tighten compressor shaft nut to 10
ft. lbs. (14 N.m).
4) Measure air gap between clutch plate and pulley assembly
in several areas. Air gap should be 0.016-0.031" (0.41-0.79 mm). If
air gap is not within specification, adjust shim thickness as
necessary. If air gap is not consistent around clutch plate, lightly
pry up or tap down on clutch plate to make corrections. To complete
installation, reverse removal procedure. Ensure A/C system operates
properly.
5) 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.
Removal (Ford "F" Series Super Duty Pickup)
1) Disconnect and isolate negative battery cable. Discharge
A/C system, using approved refrigerant recovery/recycling equipment.
Disconnect clutch coil harness connector and remove compressor. Drain
oil from compressor, and measure amount drained.
2) Using Spanner Wrench (T70P-4067-A), hold clutch plate and\
remove compressor shaft nut. See Fig. 1. If necessary, use a steering
wheel puller to remove clutch plate and shim(s).
3) Using a flat-blade screwdriver, remove pulley assembly
bearing dust cover. Remove compressor shaft key and internal bearing
snap ring. Remove external front housing snap ring.
4) Install jaws of rotor puller into pulley assembly internal
bearing snap ring groove. Install shaft protector over compressor
shaft. Install puller flange plate on jaws. Install 2 puller bolts
through puller flange plate into jaws and hand tighten. Tighten pulley
center bolt clockwise and remove pulley assembly from compressor.


A/C -H EA TE R S YSTE M

1999 D odge P ic ku p R 1500
1999 MANUAL A/C-HEATER SYSTEMS
CHRYSLER
Dakota, Durango & Ram Pickup
SPECIFICATIONS
SPECIFICATIONS








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Application Specification
Compressor Type .............................. Sanden SD-7H15 7-Cyl.
Compressor Belt Tension ........................................ ( 1)
Refrigerant (R-134a) Capacity
With Rear A/C Unit ....................................... 30 ozs.
Without Rear A/C Unit .................................... 28 ozs.
System Oil Capacity
Dakota & Ram Pickup ................................. ( 2) 8.1 ozs.
Durango
With Rear A/C Unit ................................. ( 2) 8.0 ozs.
Without Rear A/C Unit .............................. ( 2) 5.5 ozs.
System Operating Pressures ( 3)
High Side ......................... 190-220 psi (13.4-15.5 kg/cm
)
Low Side .............................. 32-40 psi (2.2-2.8 kg/cm)
( 1) - Dynamic tensioner automatically adjusts belt. Tension is okay if
indicator is within marked limits on belt tensioner.
( 2) - Use SP-20 PAG refrigerant oil.
( 3) - Measured at ambient air temperature of 80
F (27C).








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WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all SERVICE PRECAUTIONS and DISABLING &
ACTIVATING AIR BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY
article.
CAUTION: When battery is disconnected, radio will go into anti-theft
protection mode. Obtain radio anti-theft protection code from
owner prior to servicing vehicle.
DESCRIPTION
These systems are a blend-air type. Outside air enters
through a cowl at base of the windshield and flows through a plenum
chamber into blower housing. Airflow velocity is controlled by blower
speed selector switch. Air flows across evaporator and is directed by
a blend-air door to go either through or by-pass the heater core.
On Dakota and Durango, temperature control cable operates
blend-air door and allows immediate control of outlet air temperature.
It also controls operation of recirculation door. On Ram Pickup,
temperature is regulated by a blend-air servo motor controlled from
A/C-heater control panel rotary temperature dial. On all models, mode
selector switch controls vacuum-operated doors to direct conditioned
air to selected outlets.
Durango may also be equipped with an optional rear A/C unit.
The rear A/C unit consists of a blower motor and evaporator. It will
only operate while the front A/C is on. The optional rear A/C-heater
unit is controlled using fan and temperature switches.

knob pointer) is flush with base of A/C-heater control panel.
5) Rotate temperature control knob to its full clockwise
stop. Release knob. Knob pointer should be aimed at end of Red stripe.
If knob is pointed at end of Red stripe, go to next step. If knob is
not pointed at end of Red stripe, go back to step 2) and repeat
adjustment procedure.
6) Rotate temperature control knob to its full
counterclockwise stop. Release knob. If knob springs back, self-
adjuster clip securing temperature control cable to blend-air door
lever is improperly installed. See TEMPERATURE CONTROL CABLE R & I. If
knob does not spring back, temperature control cable adjustment is
complete.
TESTING
* PLEASE READ THIS FIRST *
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all SERVICE PRECAUTIONS and DISABLING &
ACTIVATING AIR BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY
article.
A/C-HEATER CONTROL PANEL TEST
1) Connect a vacuum gauge in line with Black A/C-heater
vacuum supply hose, located at tee near power brake booster (Dakota)
or in engine compartment (Durango and Ram Pickup). Position gauge so
it can be viewed from passenger compartment.
2) Start engine. While observing gauge, rotate mode control
knob to each mode position (one position at a time). Pause after each
selection. Test gauge should drop, then return to 8 in. Hg shortly
after each selection is made. If gauge reading is as specified, go to
next step. If gauge reading is not as specified, check for vacuum leak
in vacuum lines or A/C-heater control panel.
3) Move temperature control knob quickly to full hot and full
cold positions. A distinct sound of blend-air door hitting its stops
should be heard. No spring-back of knob should exist.
4) If temperature control knob operates as specified,
temperature control system is okay. On Dakota and Durango, if
temperature control knob does not operate as specified, check
condition, routing, installation, and adjustment of temperature
control cable. See TEMPERATURE CONTROL CABLE ADJUSTMENT . Also check
blend air door for proper installation, obstructions, or faulty seals.
A/C SYSTEM PERFORMANCE
1) Park vehicle out of direct sunlight. Ensure ambient
temperature is at least 70F (21C). Connect tachometer and manifold
gauge set to vehicle. Turn A/C on. Turn mode control to panel and
recirculated air positions, temperature control lever to maximum
cooling, and blower to high.
2) Start engine and allow it to run at 1000 RPM, with A/C
compressor clutch engaged. Engine should be at operating temperature
with doors, windows, and hood closed. Insert thermometer into left
center air outlet.
3) Run engine and operate system for 5 minutes. The A/C
compressor clutch may cycle, depending on temperature. If A/C
compressor clutch cycles, stop engine and disconnect negative battery
cable. Remove clutch cycling pressure switch connector. Place a jumper
wire across terminals of clutch cycling pressure switch harness
connector.
4) Connect negative battery cable. Turn A/C on. Start and

A/C SYSTEM PERFORMANCE PRESSURE SPECIFICATIONS (RAM PICKUP)








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Ambient Temp. High Side Low SideF (C) psi (kg/cm) psi (kg/cm)
70 (21) .............. 135-145 (9.5-10.2) ........ 35-40 (2.5-2\
.8)
80 (27) .............. 175-215 (12.3-15.1) ....... 40-50 (2.8-3\
.5)
90 (32) .............. 215-270 (15.1-19.0) ....... 50-60 (3.5-4\
.2)
100 (38) ............. 270-330 (19.0-23.2) ....... 60-70 (4.2-4\
.9)
110 (43) ............. 340-370 (23.9-26.0) ....... 70-80 (4.9-5\
.6)
120 (49) ............. 400-430 (28.1-30.2) ....... 85-90 (6.0-6\
.3)









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BLOWER MOTOR RELAY, HIGH SPEED BLOWER MOTOR RELAY &
COMPRESSOR CLUTCH RELAY
NOTE: Relays appear different, but testing procedures for blower
motor, high speed blower motor, and compressor clutch relays
are identical.
1) Front blower motor relay and compressor clutch relay are
located in Power Distribution Center (PDC). On Durango, high speed
blower motor relay is located in fuse/relay block under left side of
instrument panel.
2) Disconnect negative battery cable. Remove blower motor or
compressor clutch relay. Using an ohmmeter, check for continuity
between terminals No. 87A and 30 of relay. See Fig. 1 or 2. If
continuity does not exist, replace relay. If continuity exists, go to
next step.
3) Using an ohmmeter, check for continuity between terminals
No. 30 and 87 of relay. If continuity exists, replace relay. If
continuity does not exist, go to next step.
4) Measure resistance between terminals No. 85 and 86 of
relay. Reading should be 70-80 ohms. If reading is not as specified,
replace relay. If reading is as specified, go to next step.
5) Using jumper wires, connect battery voltage to terminal
No. 86 and ground terminal No. 85. See Fig. 1 or 2. Check that
continuity exists between terminals No. 30 and 87. Check that
continuity does not exist between terminals No. 87A and 30. If
continuity is not as specified, replace relay. If continuity is as
specified, relay is okay.
Fig. 1: Identifying Blower Motor Relay Terminals (Typical)
Courtesy of Chrysler Corp.

Fig. 2: Identifying Compressor Clutch Relay Terminals (Typical)
Courtesy of Chrysler Corp.
BLOWER MOTOR RESISTOR
1) Disconnect negative battery cable. Disconnect blower motor
resistor harness connector. Using an ohmmeter, check for continuity
between all 4 front blower motor resistor terminals, or 3 rear blower
motor resistor terminals. If continuity exists, go to next step. If
continuity does not exist, replace faulty blower motor resistor.
2) Check for open or short in circuits between blower motor
resistor and A/C-heater control panel. Also check for open or short in
wire between blower motor resistor and blower motor.
BLOWER MOTOR SWITCH
Front
1) Using a voltmeter, check underhood power distribution
center for battery voltage at fuse No. 5 (40-amp) on Dakota and
Durango, or fuse No. 5 (40-amp) on Ram Pickup. If battery voltage
exists, go to next step. If battery voltage does not exist, check for
open in Red wire between battery and underhood power distribution
center. If Red wire is okay, replace underhood power distribution
center.
2) Disconnect negative battery cable. Remove A/C-heater
control panel. See A/C-HEATER CONTROL PANEL R & I . Disconnect A/C-
heater control panel harness connector. Using an ohmmeter, check for
continuity between A/C-heater control panel harness connector terminal
No. 7 (Black wire on Dakota and Durango; Black/Orange on Ram Pickup)
and ground. If continuity exists, go to step 4).
3) If continuity does not exist, repair open in Black or
Black/Orange wire between A/C-heater control panel harness connector
terminal No. 7 and ground connector located at lower right corner of
instrument panel (Dakota and Durango) or behind center of instrument
panel (Ram Pickup).
4) Place mode control knob to any position except OFF. Using
an ohmmeter, check for continuity between A/C-heater control panel
connector terminal No. 7 and terminals No. 3, 4, 5, and 6 while
rotating blower motor switch. See Fig. 3.
5) If continuity does not exist at any terminal, replace
faulty A/C-heater control panel. If continuity exists as specified,
check for open in circuits between A/C-heater control panel and blower
motor resistor. Also check for an open in circuit between A/C-heater

control panel and blower motor.
Fig. 3: Identifying Blower Motor Switch Connector Terminals (Typical)\
Courtesy of Chrysler Corp.
Rear (Durango)
1) Disconnect negative battery cable. Remove rear blower
motor switch located in headliner. See BLOWER MOTOR SWITCH (REAR)
under REMOVAL & INSTALLATION. Disconnect rear blower motor switch
connector. Using an ohmmeter, check continuity between rear blower
motor switch connector Black wire and ground. If continuity exists, go
to next step. If continuity does not exist, repair open in Black wire
between rear blower motor switch connector and ground connector
located at left rear of vehicle body.
2) Place blower motor switch knob to any position except OFF.
Using an ohmmeter, check for continuity between rear blower motor
switch connector Black wire and Black/Light Blue wire, and
Black/Orange wire and Dark Green wire while rotating blower motor
switch.
3) If continuity does not exist at any terminal, replace
faulty blower motor switch. If continuity exists as specified, check
for open in circuits between blower motor switch and blower motor
resistor. Also check for an open in circuit between blower motor
switch connector and blower motor relay.
CLUTCH CYCLING PRESSURE SWITCH
Dakota & Ram Pickup
1) Locate clutch cycling pressure switch on side or top of
A/C accumulator. Ensure clutch cycling pressure switch is properly
installed on A/C accumulator fitting. Ensure system pressure is
correct. See A/C SYSTEM PERFORMANCE test.
2) Start and run engine with A/C on. If clutch cycles, turn
engine off and disconnect negative battery cable. Disconnect clutch
cycling pressure switch connector. Place a jumper wire across
terminals of clutch cycling pressure switch harness connector. Connect
negative battery cable. Connect manifold gauge set. Set A/C-heater