light DODGE RAM 1999 Service Repair Manual

Fig. 8: Removing Shift Indicator (Ram Van & Ram Wagon)
Courtesy of Chrysler Corp.
HEADLIGHT SWITCH
Removal & Installation (Ram Pickup)
1) Disconnect negative battery cable. Open power outlet door
and remove instrument cluster bezel retaining screw. Pry cluster bezel
from clips securing it to instrument panel. See Fig. 3. Disconnect
electrical connectors from power outlet to cluster bezel. Remove
cluster bezel.
2) Remove 3 screws and headlight switch. Disconnect
electrical connectors. Pull knob and stem to stop. Hold down button on
top of switch and remove switch. Remove 2 screws and bezel. To install
switch, reverse removal procedure.
Removal & Installation (Ram Van & Ram Wagon)
1) Disconnect negative battery cable. Turn ignition switch to
UNLOCK position and shift gear selector to "1" position. On models
equipped with tilt steering wheel, tilt wheel to lowest position. On
all models, pry cluster bezel away from clips securing it to
instrument panel. See Fig. 4. Pull left side of bezel far enough to
clear trip odometer reset button and remove bezel.
2) Remove switch bezel attaching screws. Remove switch, and
disconnect wiring harness. Pull headlight switch knob to on position.
Hold down button on top of switch and remove knob and shaft assembly.
Remove switch spanner nut and remove bezel from switch. To install
switch, reverse removal procedure.

M * Lago Alberto, Mexico
12-17 - Serial Number
* Sequential Production Number
MAINTENANCE SERVICE INFORMATION
LIGHT & HEAVY DUTY SERVICE DEFINITIONS
Maintenance service is recommended at different mileage
intervals based on Gross Vehicle Weight Rating (GVWR). See appropriate\
SERVICE SCHEDULES article.
Light Duty
Vehicles with GVWR of 8500 lbs. or less.
Heavy Duty
Vehicles with GVWR of 8501 lbs. or more.
SEVERE & NORMAL SERVICE DEFINITIONS
Service is recommended at mileage intervals based on vehicle
operation. Normal Service and Severe Service schedules are based on
the following primary operating conditions:
Normal Service
* Driven More Than 10 Miles Daily
* NO Severe Service Operating Conditions
Severe Service
NOTE: Use the Severe Service schedule if the vehicle to be serviced
is operated under ANY (one or more) of these conditions:
* Frequent Short Trips Of Less than 5 Miles (8 KM)
* Frequent Driving In Dusty Conditions
* Frequent Trailer Towing
* Frequent Idling
* More Than 50% Of Your Driving Is At Sustained High Speeds
During Hot Weather, Above 90
\bF (32\bC)
SERVICE POINT LOCATIONS

refer to the 5.9L V8 TURBO DIESEL - VIN [D] article.
in the ENGINE MECHANICAL section.
Drain fuel/water separator by pushing up on the valve
located on the bottom of the fuel filter until clear fuel
is visible. Drain fuel into a container and follow proper
disposal procedures.
CAUTION: DO NOT drain fuel/water separator when engine is running or
hot. Allow engine to cool before draining. Verify that the
WATER IN FUEL light on instrument panel is OFF.
ADDITIONAL SERVICE INFORMATION - CNG MODELS
Fig. 11: Locating CNG Components
Courtesy of Chrysler Corp.

BR3500 (8 Stud Dual Wheel)........................ 145 (195)








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BATTERY SPECIFICATIONS
Vehicle is factory equipped with a maintenance free battery.
The top of the battery is permanently sealed, and water never has to
be added, and periodic maintenance is not required either. But,
periodically check the battery terminals and battery hold-down bracket
for corrosion. Replace with a battery of the same group number as
shown on original battery's label.
CAUTION: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure. See COMPUTER
RELEARN PROCEDURES article in the GENERAL INFORMATION
section.
CAUTIONS & WARNINGS
SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG)
NOTE: See the AIR BAGS article in the ACCESSORIES/SAFETY EQUIPMENT
Section.
Modifications or improper maintenance, including incorrect
removal and installation of the Supplemental Restraint System (SRS),
can adversely affect system performance. DO NOT cover, obstruct or
change the steering wheel horn pad in any way, as such action could
cause improper function of the system. Use only plain water when
cleaning the horn pad. Solvents or cleaners could adversely affect the
air bag cover and cause improper deployment of the system.
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all warnings and service precautions. See
appropriate AIR BAGS article in ACCESSORIES/SAFETY EQUIPMENT.
WARNING: Any maintenance performed on or near the components of the
SRS must be performed only by an authorized dealer.
Do not permit anyone else to service, inspect maintain, or
service any SRS components or wiring. Similarly, no part of
the SRS should ever be handled or disposed of by anyone
except an authorized dealer.
Improper work on the SRS components or wiring could result in
inadvertent deployment of the airbags or could render the SRS
system inoperative. Either situation could result in serious
injury
WARNING: If the car has had any front-end damage, have the SRS system
inspected by an authorized dealer to ensure it is working
properly.
WARNING: If any of the following conditions occur, the SRS is not
working properly. Immediately have it inspected by an
authorized dealer:
* The SRS warning light does not illuminate when you start
the car.
* The SRS warning light does not go off after about 7 seconds.
* The SRS warning light illuminates while driving.

been submerged in water. Water can enter through the axle
vent hole and contaminate the lubricant.
BATTERY WARNING
WARNING: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure.
WARNING: Batteries produce flammable hydrogen gas. Keep flames and
sparks away from the battery or and explosion may occur.
Never smoke when working in the vicinity of the battery.
WARNING: When checking or servicing the battery, disconnect the
negative cable. Be careful not to cause a short circuit by
allowing metal objects to contact the battery posts and the
vehicle at the same time.
REPLACING BLOWN FUSES
CAUTION: Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical
system. Be sure to use fuse with the correct indicated
amperage rating. The use of an incorrect amperage rating fuse
may result in a dangerous electrical system overload.
BRAKE PAD WEAR INDICATOR
Indicator will cause a squealing or scraping noise, warning
that brake pads need replacement.
BRAKE HOSES
WARNING: Worn brake hoses can burst and cause brake failure. If
any sign of cracking, scuffing, or worn spots are found,
replace the brake hoses immediately.
BRAKE FLUID
WARNING: The use of incorrect fluid in the brake system may cause
damage to components. DO NOT use any fluid other than DOT-3
brake fluid. DO NOT use reclaimed fluid or fluid that has
been stored in old or open containers. It is essential that
foreign particles and other liquids are kept out of the
brake fluid reservoir.
CATALYTIC CONVERTER
CAUTION: Continued operation of vehicle with a severe malfunction
could cause converter to overheat, resulting in possible
damage to converter and vehicle.
COOLANT
CAUTION: To avoid possible damage to vehicle use only ethylene-glycol
based coolants with a mixture ratio from 50-70% anti-freeze.
DO NOT use 100% anti-freeze as it will cause the formation
of cooling system deposits.
DIESEL FUEL ANTI-FUNGAL ADDITIVES

F1 - Not Used
F2 - 30 Amp (Lt. Green)
Blower Motor
CB1 - 30 Amp (Circuit Breaker)
Power Windows
CB2 - 30 Amp (Circuit Breaker)
Power Seats
1 - 20 Amp (Yellow)
Power Outlet
2 - Not Used
3 - Not Used
4 - Not Used
5 - 20 Amp (Yellow)
Cigar Lighter
6 - 20 Amp (Yellow)
Turn Signal Flasher
7 - 15 Amp (Lt. Blue)
Radio
8 - 20 Amp (Yellow)
Windshield Wipers
9 - 10 Amp (Red)
Fuel Pump Relay, A/C Compressor Clutch Relay
Automatic Shutdown Relay, Transmission Overdrive
Solenoid, EGR Solenoid, Powertrain Control Module (PCM)
Ignition Module
High Pressure Fuel Shut-Off Solenoid Relay (CNG Models Only)
EGR Solenoid (CNG Models Only)
10 - Not Used
Vehicle Speed Control
11 - 10 Amp (Red)
Buzzer, Overhead Console
12 - 15 Amp (Lt. Blue)
Airbag Diagnostic Module, Cluster, Message Center,
13 - 5 Amp (Tan)
Illumination
14 - 20 Amp (Yellow)
RWAL and ABS Module
15 - 15 Amp (Lt. Blue)
Automatic Day/Night Mirror, Back-up Lights,
Daytime Running Lamps
16 - 15 Amp (Lt. Blue)
Airbag Diagnostic Module
17 - 15 Amp (Lt. Blue)
Ignition Off Draw, Radio and Clock Memory
18 - 15 Amp (Lt. Blue)
Parking Lamps
19 - 20 Amp (Yellow)
Power Door Locks
20 - 15 Amp (Lt. Blue)
Stop Lamps
POWER DISTRIBUTION CENTER

Fig. 20: Underhood Power Distribution Center
Courtesy of Chrysler Corp.
WARNING: Always disconnect battery ground cable before servicing
"high-current fuses. It is recommended that "high-current"
fuses be replaced by a qualified technician.
Power Distribution Center Relay & Fuse Identification
A - Starter Relay
B - Trailer Lights Relay
C - Auto Transmission Relay
D - Anti-Lock Brake System Relay
E - Auto Shutdown Relay
F - Air Conditioning Clutch Relay
G - Horn Relay
H - Fuel System Relay
J - ABS Warning Light Relay
K - Fog Lamp 2 Relay
L - Fog Lamp 1 Relay
1 - 30 Amp (Pink)
Engine Control
2 - 40 Amp (Green)
Ignition Run/Accessory
3 - 40 Amp (Green)
Ignition Run
4 - 50 Amp (Red)
Instrument Panel, Horn, Parking Lights
5 - 20 Amp (Blue)
Fuel Pump
6 - 30 Amp (Pink)
Trailer Lights
7 - 40 Amp (Green)
Stop/Headlight
8 - 40 Amp (Green)
ABS Pump
9 - 20 Amp (Yellow)
Hazard Lights
10 - 20 Amp (Yellow)
Horn/AC
11 - 15 Amp (Blue)

METR IC C O NVER SIO NS

1999 D odge P ic ku p R 1500
GENERAL INFORMATION
METRIC CONVERSIONS
METRIC CONVERSIONS
Metric conversions are making life more difficult for the
mechanic. In addition to doubling the number of tools required,
metric-dimensioned nuts and bolts are used alongside English
components in many new vehicles. The mechanic has to decide which tool
to use, slowing down the job. The tool problem can be solved by trial
and error, but some metric conversions aren't so simple. Converting
temperature, lengths or volumes requires a calculator and conversion
charts, or else a very nimble mind. Conversion charts are only part of
the answer though, because they don't help you "think" metric, or
"visualize" what you are converting. The following examples are
intended to help you "see" metric sizes:
LENGTH
Meters are the standard unit of length in the metric system.
The smaller units are 10ths (decimeter), 100ths (centimeter), and
1000ths (millimeter) of a meter. These common examples might help you
to visualize the metric units:
* A meter is slightly longer than a yard (about 40 inches).
* An aspirin tablet is about one centimeter across (.4 inches).
* A millimeter is about the thickness of a dime.
VOLUME
Cubic meters and centimeters are used to measure volume, just
as we normally think of cubic feet and inches. Liquid volume
measurements include the liter and milliliter, like the English quarts
or ounces.
* One teaspoon is about 4 cubic centimeters.
* A liter is about one quart.
* A liter is about 61 cubic inches.
WEIGHT
The metric weight system is based on the gram, with the most
common unit being the kilogram (1000 grams). Our comparable units are
ounces and pounds:
* A kilogram is about 2.2 pounds.
* An ounce is about 28 grams.
TORQUE
Torque is somewhat complicated. The term describes the amount
of effort exerted to turn something. A chosen unit of weight or force
is applied to a lever of standard length. The resulting leverage is
called torque. In our standard system, we use the weight of one pound
applied to a lever a foot long, resulting in the unit called a foot-
pound. A smaller unit is the inch-pound (the lever is one inch long).
Metric units include the meter kilogram (lever one meter long
with a kilogram of weight applied) and the Newton-meter (lever one


MIR RO RS - P O W ER

1999 D odge P ic ku p R 1500
1999 ACCESSORIES & EQUIPMENT
CHRY - Power Mirrors
Caravan, Dakota, Durango, Ram Pickup, Ram Van, Ram Wagon,
Town & Country, & Voyager
DESCRIPTION
Outside power rear view mirrors consist of door-mounted
mirrors with internal motor drive and backing plate. On Caravan, Town
& Country, and Voyager, mirrors are controlled by a rocker switch for
left or right mirror selection and a platform button for up, down,
right and left movement. On Dakota, Durango, Ram Pickup, Ram Van and
Ram Wagon, mirrors are controlled by a single, multifunction,
joystick-type switch assembly. On all models, mirror motors are
integral with mirror assemblies and cannot be serviced separately. On
Dakota and Durango, fold-away rear view mirrors are optional.
Dakota, Durango and Ram Pickup are equipped with an automatic
dimming day/night inside mirror. The mirror uses 2 photocell sensors
to monitor ambient and rear facing light levels. The mirror
automatically adjusts its reflectance to reduce headlight glare from
vehicles approaching from the rear. The mirror is controlled by an
off/on switch located on the mirror bottom.
Caravan, Ram Pickup, Town & Country and Voyager have optional
heated outside mirrors. On Caravan, Town & Country and Voyager, heated
mirror is activated whenever the rear defogger is on. On Ram Pickup,
heated mirror is activated by switch in dash. A timer turns off mirror
heater after about 10 minutes.
COMPONENT TESTS
AUTOMATIC DAY/NIGHT INSIDE MIRROR
1) Turn ignition switch to ON position with transmission in
Neutral or Park. Place mirror switch in ON position (switch LED
illuminated). Cover forward facing sensor with a dark cloth or tape to
exclude any ambient light. See Fig. 1.
2) Shine a light into rear-facing sensor. Observe whether or
not mirror darkens. With mirror darkened, place transmission in
Reverse. Mirror should return to normal. If conditions of steps 1) and
2) are met, mirror is operating correctly. If conditions are not met,
go to next step.
3) Turn ignition on. Check for battery voltage at fuse No. 11
in junction block. If battery voltage exists on both sides of fuse, go
to next step. If battery voltage does not exist, repair circuit to
junction block. See WIRING DIAGRAMS. If fuse is blown, repair short
circuit and replace fuse.
4) Check for battery voltage at day/night mirror wire
connector terminal No. 1 (Dark Blue/White wire). If battery voltage
exists, go to next step. If battery voltage does not exist, repair
open circuit between mirror and junction block.
5) Check for continuity between ground and day/night mirror
wire connector terminal No. 2 (Black wire). If continuity exists, go
to next step. If continuity does not exist, repair open ground
circuit.
6) Check for battery voltage at day/night mirror wire
connector terminal No. 3 (Violet/Black wire) with transmission in
Reverse. If battery voltage exists, replace mirror. If battery voltage
does not exist, check back-up light circuit. See WIRING DIAGRAMS.

Fig. 1: Identifying Automatic Day/Night Mirror
Courtesy of Chrysler Corp.
POWER MIRROR MOTOR
Caravan, Town & Country, & Voyager
Disconnect harness connector from mirror and headlight
switch. Using 2 jumper wires, connect one jumper to a 12-volt source
and the other jumper wire to a good ground. Connect other end of
jumper wires to specified switch terminals as specified. See POWER
MIRROR MOTOR TEST (CARAVAN, TOWN & COUNTRY, & VOYAGER) table. If