instrument panel DODGE RAM 1999 Service User Guide

TEMPERATURE CONTROL CABLE R & I
Removal (Dakota & Durango)
Disconnect negative battery cable. Disconnect but DO NOT
remove instrument panel. See INSTRUMENT PANEL. Disconnect temperature
control cable from A/C-heater control panel. Disconnect temperature
control cable from flag retainer located at top of A/C-heater assembly
housing. See Fig. 7. Remove temperature control cable self-adjuster
clip and temperature control cable.
Installation
1) Before installing temperature control cable, ensure that
self-adjuster clip is positioned as indicated. See Fig. 8.
Measurements must be made with cable end bottomed against flag
retainer on A/C-heater control panel end of cable housing.
2) Measure distance between center of self-adjusting clip and
end of cable flag retainer. If distance is not as specified, adjust
self-adjuster clip. To complete installation, reverse removal
procedure.
Fig. 7: Removing Control Cable Flag From Receiver (Typical)
Courtesy of Chrysler Corp.
Fig. 8: Adjusting Temperature Control Cable (Dakota & Durango)
Courtesy of Chrysler Corp.

BLOWER MOTOR VIBRATION
Possible causes of blower motor vibration include:
* Improper blower motor mounting.
* Improper blower wheel or fan mounting.
* Blower wheel or fan out of balance.
* Blower motor faulty.
BLOWER MOTOR NOISE
Possible causes of blower motor noise include:
* Foreign material in blower motor housing.
* Foreign material in A/C-heater housing.
* Improper blower motor mounting.
* Improper blower wheel or fan mounting.
* Blower motor faulty.
VACUUM CONTROL SYSTEM DIAGNOSIS
VACUUM CONTROL ONE-WAY CHECK VALVE
NOTE: Some models use brake booster check valve for vacuum source.
These models do not use another in-line vacuum check valve.
1) In engine compartment, locate Black vacuum hose that runs
from brake booster check valve or intake manifold, through firewall
near heater hoses or expansion valve. This supply vacuum hose goes to
A/C-heater control panel vacuum switch.
2) Within Black vacuum hose, disconnect and remove check
valve near intake manifold or brake booster. Connect vacuum gauge to
an external vacuum pump. Start vacuum pump. Plug end of hose probe on
vacuum gauge. Adjust bleed valve on vacuum gauge to obtain an exact
vacuum reading of 8 in. Hg.
3) Unplug and plug end of hose probe on vacuum gauge several
times to ensure exact vacuum reading. Connect vacuum gauge hose probe
to control panel side of check valve. Vacuum gauge reading should be 8
in. Hg. Replace check valve if vacuum leak exists.
4) Connect vacuum gauge hose probe to engine side of check
valve. Vacuum should flow through check valve. Replace check valve if
operation is not as described.
VACUUM CONTROLS
1) This test checks for proper function of control panel
vacuum circuits. Perform steps 1) through 4) under VACUUM CONTROL ONE-\
WAY CHECK VALVE.
2) Connect vacuum gauge hose probe to Black vacuum hose end
that leads to A/C-heater control panel switch. Position vacuum gauge
so gauge reading can be observed from inside vehicle.
3) Operate A/C-heater controls (sliding lever or push
buttons) in all mode positions (floor, defrost, panel, etc.). Pause
after each selection to allow vacuum actuators or motors to energize
and stabilize. Record vacuum gauge reading at each selection.
4) After each selection, vacuum reading should be 7.5-8 in.
Hg. Maximum vacuum reading drop is .75 in. Hg. If proper vacuum
reading cannot be obtained, vacuum leak exists in selected circuit.
5) To check for vacuum leak(s), disconnect 7-way A/C-heater
control panel vacuum harness connector. See Fig. 1. If necessary,
remove control panel from instrument panel to access A/C-heater
control panel vacuum harness connector, or remove lower instrument


D - A D JU STM EN TS - C NG & G ASO LIN E

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - On-Vehicle Adjustments - Trucks & RWD Vans - CNG & Gas
Dakota, Durango, Ram Pickup, Ram Van, Ram Wagon
ENGINE MECHANICAL
Before performing any on-vehicle adjustments to fuel or
ignition systems, ensure engine mechanical condition is okay.
VALVE CLEARANCE
NOTE: All engines use hydraulic lifters. No adjustments are
required.
IGNITION TIMING
On all models, ignition timing is controlled by Powertrain
Control Module (PCM). Ignition timing is nonadjustable. DO NOT attempt\
to adjust ignition timing by rotating distributor.
NOTE: On Dakota 3.9L, 5.2L and 5.9L, Durango, Ram Pickup, Ram Van
and Ram Wagon, if distributor is rotated, fuel system
synchronization will be changed. If distributor is removed or
rotated, check fuel system synchronization. See procedures
under FUEL SYSTEM SYNCHRONIZATION under FUEL SYSTEM.
FUEL SYSTEM
FUEL SYSTEM SYNCHRONIZATION
NOTE: Fuel system synchronization is controlled by position of the
distributor. Rotating distributor WILL NOT change ignition
timing, but will change fuel system synchronization. Fuel
system synchronization should be checked anytime distributor
is removed or rotated.
Dakota 3.9L, 5.2L & 5.9L, Durango, Ram Pickup, Ram Van & Ram
Wagon
1) Connect scan tool to Data Link Connector (DLC). DLC is
located below driver's side of instrument panel, near steering column.
See Fig. 1 , 2 or 3.
2) Using scan tool manufacturer's instructions, access SET
SYNC display on scan tool. Following scan tool displays, start engine.
Warm engine to normal operating temperature. Vehicle must be in closed
loop. With engine idling, if scan tool displays IN RANGE along with
0
, this indicates correct distributor location. The degree reading
displayed on scan tool indicates the fuel synchronization, not
ignition timing.
3) If scan tool display is correct, shut engine off. Remove
scan tool. If scan tool does not display IN RANGE along with 0
, go to
next step.
4) If scan tool displays a plus (+) or minus (-) sign next\
to
the degree number, and/or the degree number displayed is not zero,
loosen but DO NOT remove distributor hold-down bolt.
5) Rotate distributor until scan tool displays IN RANGE.
Continue to rotate distributor until a reading as close as possible to

2) Disconnect vacuum line at PCV valve located in valve
cover. Install .185" fixed orifice Air Metering Fitting (6714) into
disconnected vacuum line in place of PCV valve.
3) Disconnect purge vacuum hose from passenger's side front
corner of throttle body, next to MAP sensor. Place cap on vacuum hose
fitting on throttle body.
4) Connect scan tool to Data Link Connector (DLC) located
below driver's side of instrument panel, near steering column. See
Fig. 1, 2 or 3.
5) Start engine and warm engine to normal operating
temperature. Using scan tool manufacturer's instructions, select
SYSTEM TEST and then access the MINIMUM AIRFLOW display on scan tool.
When accessed, scan tool will count down to stabilize idle RPM and
display minimum airflow idle RPM. Minimum airflow idle RPM should be
500-900 RPM.
6) Shut engine off. If minimum airflow idle RPM is correct,
throttle body is okay. Go to next step. If minimum airflow idle RPM is
not within specification, using approved cleaner, clean throttle body
and recheck minimum airflow idle RPM. If correct minimum airflow idle
RPM cannot be obtained, replace throttle body. Go to next step.
7) Remove air metering fitting. Reinstall vacuum hoses as
necessary. Reinstall air duct on throttle body. Remove scan tool.
Ram Pickup 8.0L
Throttle body minimum airflow cannot be checked on this
application.
THROTTLE POSITION SENSOR
NOTE: Throttle Position (TP) sensor is nonadjustable. Use following\
procedure to check TP sensor calibration. For complete
testing of TP sensor and wiring circuit, see SELF-DIAGNOSTICS
- JEEP, TRUCKS & RWD VANS article.
Dakota, Ram Pickup, Ram Van & Ram Wagon
1) Remove components for access to electrical connector at TP
sensor mounted on throttle body. With electrical connector installed
on TP sensor, turn ignition on with engine off. DO NOT start engine.
2) Using digital volt-ohmmeter, measure voltage at center
terminal on electrical connector for TP sensor with throttle valve
closed (idle position). Voltage should be greater than .35 volt, but
less than .90 volt.
3) Slowly open throttle to full throttle and note voltage
reading. Voltage should smoothly increase to less than 4.50 volts.
Replace TP sensor if voltage is not within specification.

AIR B AG R ESTR AIN T S YSTE M
1999 D odge P ic ku p R 1500
1999 AIR BAG RESTRAINT SYSTEMS
DaimlerChrysler Corp.
Dodge: Ram Pickup
DESCRIPTION & OPERATION
* PLEASE READ THIS FIRST *
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all WARNINGS and SERVICE PRECAUTIONS.
Supplemental Restraint System (SRS) is designed to work in
conjunction with seat belts. SRS helps to reduce the risk or severity
of serious injury during a front-end collision. Driver-side air bag is
stored in a module in steering wheel hub. All models are equipped with
passenger-side air bags. Passenger-side air bag is stored in the
instrument panel, above glove box. All air bags are covered by a pad
bearing the air bag SRS logo.
Air bag(s) inflate and deflate within 1/10th of a second of
impact sensor switches closing. This creates a cushion of air between
driver and steering wheel and passenger and instrument panel.
System consists of an AIR BAG warning light, clockspring,
driver-side and passenger-side air bag modules, Air Bag Control Module
(ACM), one impact sensor (located inside ACM) and an energy reserve
capacitor. The ACM monitors system, stores fault codes (messages) and
provides information to AIR BAG warning light and Data Link Connector
(DLC). When a malfunction occurs, a fault code is stored and AIR BAG
warning light is activated for more than 12 seconds.
When impact sensor registers sufficient deceleration force
during a front-end collision, an electrical charge is sent from ACM to
air bag module inflator via the clockspring. Inflator actuates and
produces nitrogen gas, which inflates air bag(s).
AIR BAG WARNING LIGHT
Whenever ignition switch is in RUN or START position, AIR BAG
warning light on instrument panel will illuminate for 6-8 seconds and
then turn off. This signifies ACM has checked the system and found
that it is functioning properly. If AIR BAG warning light illuminates
for 12 seconds or more, stays on all the time or does not come on, a
system malfunction exists and trouble code will be stored.
IMPACT SENSOR
All models have one impact sensor located inside ACM. Impact
sensor is an accelerometer that measures deceleration. During a front-
end collision, a signal is sent that completes an electrical circuit
to inflators. Inflators actuate and produce nitrogen gas, which
inflates each air bag. Impact sensor is calibrated for a specific
vehicle and react to severity and direction of vehicle impact.
AIR BAG MODULE
WARNING: DO NOT attempt to disassemble air bag modules. Air bag
modules are not serviceable.
Driver-Side
Air bag module is mounted on front face of steering wheel. A

protective cover is fitted to front of air bag module bearing the SRS
air bag logo. Air bag module contains air bag cushion, inflator and
supporting components. Air bag module is a sealed unit and is not
serviceable. The module inflator assembly produces nitrogen gas to
fill air bag cushion when a small amount of current from ACM is
applied to the ignitor assembly. Gas pressure builds and discharges
from inflator through a diffuser and screen assembly, forcing steering
wheel cover to burst along its seams until air bag is fully inflated.
Once air bag cushion is fully inflated, gas escapes from bag through
vents, away from driver.
Passenger-Side
Air bag module is mounted to instrument panel mounting
bracket. Module is covered by a protective door bearing the SRS air
bag logo. When supplied an electrical signal, inflator will discharge
argon gas directly into air bag. When air bag inflates, protective
door will pivot aside allowing air bag to deploy.
AIR BAG CONTROL MODULE (ACM)
ACM is located under instrument panel, on transmission
tunnel. Impact sensor, energy reserve capacitor and On-Board
Diagnostics (OBD) are an integral part of ACM. ACM monitors critical
input and output circuits within air bag system, ensuring they are
operating correctly. Some circuits are tested continuously; others are
checked only under certain conditions. ACM provides information about
air bag system through AIR BAG warning light and Data Link Connector
(DLC). When diagnostic trouble code (fault message) is stored, AIR B\
AG
warning light will be activated for 12 seconds or more.
DATA LINK CONNECTOR (DLC)
DLC is located under left side of instrument panel, left of
steering column. DLC is used to access SRS on-board diagnostics.
CLOCKSPRING
Clockspring connects air bag module to steering column
wiring, completing air bag system circuit. See Fig. 1. Inside
clockspring is a flat, ribbon-like tape of conductive material, which
winds and unwinds with steering wheel movement. Clockspring is the
most fragile part of air bag system. Clockspring must be centered
properly to allow 1 1/2 steering wheel turns in either direction. If
clockspring is not centered properly, it can break from stretching or
fatigue.
Fig. 1: Identifying Clockspring Assembly
Courtesy of DaimlerChrysler Corp.

PASSENGER AIR BAG DISARM (PAD) SWITCH
PAD switch is mounted on instrument panel. Switch allows
passenger-side airbag module to be disarmed when rear facing child
safety seat is being used. PAD switch is operated with ignition key.
SYSTEM OPERATION CHECK
Turn ignition on and observe AIR BAG warning light. AIR BAG
warning light should illuminate for 6-8 seconds and then go out,
indicating system is functioning properly. If AIR BAG warning light
either fails to illuminate or illuminates continuously, a system
malfunction exists. Perform self-diagnostics. See DIAGNOSIS & TESTING.
After completing necessary repairs, turn ignition switch to
ON position. Ensure no one is inside vehicle, then connect negative
battery cable. Using DRB, erase stored Diagnostic Trouble Codes (DTC).\
See DIAGNOSIS & TESTING .
SERVICE PRECAUTIONS
These precautions should be observed when working with air
bag systems:
* Disable air bag system before servicing any air bag system
or steering column component. Failure to do this could
result in accidental air bag deployment and possible
personal injury. See DISABLING & ACTIVATING AIR BAG SYSTEM .
* Back-up power supply maintains deployment voltage for about
2 minutes after battery is disconnected. When disabling air
bag system, always wait at least 2 minutes after
disconnecting battery cables to resume procedure.
* After repairs, ensure AIR BAG warning light works
properly and no system faults are indicated. See
SYSTEM OPERATION CHECK .
* Always wear safety glasses when servicing or handling an
air bag.
* All SRS component fasteners are specially coated and are
designed with a specific function. Never replace SRS
component fasteners with other than original equipment parts.
* Air bag module must be stored in its original special
container until used for service. It must be stored in a
clean, dry, place, away from sources of extreme heat, sparks
and high electrical energy.
* When placing a live air bag on a bench or other surface,
always face air bag and trim cover up, away from surface.
This will reduce motion of module if accidentally deployed.
* After deployment, air bag surface may contain deposits of
sodium hydroxide, which irritates skin. Always wear safety
glasses, rubber gloves, and long-sleeved shirt during
clean-up and wash hands using mild soap and water. Follow
correct disposal procedures. See DISPOSAL PROCEDURES.
* Because of critical system operating requirements, DO NOT
attempt to service any air bag components. Corrections are
only made by replacing defective part.
* Electrical sources should never be allowed near inflator on
back of air bag module.
* When carrying a live air bag module, trim cover should be
pointed away from your body to minimize injury in case of
deployment.
* When testing voltage or continuity at Air Bag Control Module

foot wires to terminals of a 12-volt battery. After air bag module
deploys, let module cool off and allow dust to settle before
approaching.
POST-COLLISION INSPECTION
When a vehicle has been involved in a collision, certain
components of the passive restraint system must be inspected or
replaced. See PASSIVE RESTRAINT SYSTEM INSPECTION article in the
GENERAL INFORMATION section for post-collision inspection information.
REMOVAL & INSTALLATION
* PLEASE READ THIS FIRST *
WARNING: Failure to follow air bag service precautions may
result in air bag deployment and personal injury. See
SERVICE PRECAUTIONS . After component replacement,
ensure proper system operation. See SYSTEM OPERATION CHECK.
CAUTION: When battery is disconnected, vehicle computer and memory
systems may lose memory data. Driveability problems may
exist until computer systems have completed a relearn cycle.
See COMPUTER RELEARN PROCEDURES in GENERAL INFORMATION
before disconnecting battery.
AIR BAG CONTROL MODULE (ACM)
WARNING: ACM contains impact sensor, which enables SRS to activate air
bag. To avoid accidental air bag deployment, DO NOT connect
ACM electrically to system unless it is bolted to vehicle.
Removal
1) Before proceeding, see SERVICE PRECAUTIONS. Disable air
bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove bottom
of center console (ACM trim cover).
2) On M/T models, remove center console from floor panel
transmission tunnel. On A/T models, remove screws securing trim cover
to ACM mounting bracket. See Fig. 2. Pull top of trim cover rearward
to release snap clips from instrument panel support bracket.
3) On all models, loosen but do not remove screws on sides
that secure instrument panel support bracket to ACM mounting bracket.
See Fig. 3 .
4) Remove nuts securing support bracket to studs on lower
instrument panel. Disconnect wire harness retainer from hole in
support bracket. Pull top of support bracket away from instrument
panel studs and fold down over ACM until it is laying on floor panel.
Unplug wire harness connector from ACM.
CAUTION: Always replace ACM and ACM mounting bracket as an assembly.
Replacement ACM includes a NEW mounting bracket. DO NOT mount
NEW ACM to old mounting bracket.
5) Remove screws securing mounting bracket to floor panel
transmission tunnel. Remove ACM, mounting bracket and support bracket
as a unit from floor panel.
Installation
To complete installation, reverse removal procedure. Install
ACM with arrow pointing toward front of vehicle. Connect ACM
connectors, ensuring connectors are locked into position. Tighten ACM

CAUTION: When removing a deployed air bag, wear eye protection, rubber
gloves and a long-sleeve shirt. Powder residue from air bag
deployment may irritate skin and eyes.
CAUTION: Before removing steering wheel, position front wheels in
straight-ahead position and lock steering column by removing
ignition key. Failure to do so could damage clockspring or
cause clockspring to be off-centered. DO NOT hammer on
steering wheel during removal, or collapsible column could be
damaged.
Removal
1) Before proceeding, see SERVICE PRECAUTIONS. Disable air
bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Air bag module
is mounted on face of steering wheel. Ensure wheels are pointed
straight-ahead and steering wheel is locked.
2) Remove air bag module-to-steering wheel screws from back
side of steering wheel. Lift air bag module and disconnect electrical
connectors from rear of module.
Installation
Connect air bag, cruise control and horn harness connectors
to rear of air bag module. Secure module to steering wheel. Tighten
air bag module-to-steering wheel screws to specification. See
TORQUE SPECIFICATIONS . DO NOT connect negative battery cable at this
time. Go to SYSTEM OPERATION CHECK .
PASSENGER-SIDE AIR BAG MODULE
Removal
1) Before proceeding, see SERVICE PRECAUTIONS. Disable air
bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .
2) Open glove box. Holding glove box door, push center of
glove box bin towards front of vehicle. Flex glove box bin far enough
so glove box stops will clear sides of instrument panel opening. Roll
glove box down until stop bumpers are beyond sides of instrument panel
opening. Release bin. Lift bottom of glove box upward to disengage
hinge hooks form hinge pins.
3) Remove 3 screws securing instrument panel glove box
opening upper trim strip to instrument panel glove box opening upper
reinforcement, then remove trim strip. Remove 4 screws that secure 2
plastic support brackets of passenger-side air bag door panel outlet
housing to glove box opening upper reinforcement.
4) Reach through and above glove box opening to access and
disconnect air bag module harness connector. Remove 2 screws securing
passenger-side air bag module front bracket to instrument panel
structural support. Remove 3 screws securing passenger-side air bag
module rear bracket to glove box opening upper reinforcement.
5) Using trim stick, gently pry passenger-side air bag door
(starting at lower left edge) away from instrument panel top cover.
Remove air bag module, air bag door and panel outlet housing and
barrel assembly from instrument panel as a unit.
Installation
To install, reverse removal procedure. Ensure air bag door is
securely attached to instrument panel. Ensure air bag harness
connector latches fully engaged. DO NOT connect negative battery cable
at this time. Go to SYSTEM OPERATION CHECK .
CLOCKSPRING
CAUTION: Failure to position wheels in the straight-ahead position
with steering wheel locked when removing steering wheel could

damage clockspring and/or require clockspring to be
readjusted.
NOTE: Clockspring is self-centering and will automatically lock in
the centered position when steering wheel is removed.
Adjustment is only required if centering position is
disturbed.
Removal
1) Before proceeding, see SERVICE PRECAUTIONS. Disable air
bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .
2) Clockspring is located behind steering wheel. See Fig. 1.
Ensure front wheels are in straight-ahead position. Lock steering
wheel. Remove air bag module. See AIR BAG MODULE.
3) Remove steering wheel nut. Using appropriate steering
wheel puller, remove steering wheel. When steering wheel is removed,
self-centering clockspring will automatically lock in place. Remove
upper and lower steering column shrouds to gain access to clockspring
wiring.
4) Remove knee bolster (if equipped). Disconnect Yellow 2-wa\
y
clockspring harness connector between clockspring and instrument panel
wiring harness, at base of steering column. See Fig. 13. Remove
clockspring by releasing 2 tabs on side of clockspring. Clockspring
cannot be repaired and must be replaced if faulty.
Installation
1) Snap clockspring onto steering column. If clockspring
centering adjustment is disturbed, adjust clockspring before
installing steering wheel. See CLOCKSPRING CENTERING under
ADJUSTMENTS. Connect clockspring wiring connectors. Install steering
column covers. Install knee bolster (if removed).
2) Position steering wheel on steering column. Ensure flats
on steering wheel hub fit formations on inside of clockspring. Pull
clockspring, cruise control switch (if equipped) and horn wires
through lower large holes and upper small holes in steering wheel.
3) Install steering wheel retaining nut and tighten to 45 ft.
lbs. (61 N.m). Connect horn and cruise control wires (if equipped).
Connect clockspring wire to air bag module. To ensure complete
connector connection, latching arms must be visible on top of
connector housing. DO NOT connect negative battery cable at this time.
Go to SYSTEM OPERATION CHECK .
PASSENGER AIR BAG DISARM (PAD) SWITCH
Removal & Installation
1) Before proceeding, see SERVICE PRECAUTIONS. Disable air
bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .
2) If vehicle is equipped with automatic transmission, turn
ignition switch to UNLOCK position, set parking brake and place
transmission selector lever in LOW position. Tilt steering column to
lowest position (if equipped). Using trim stick, gently pry around
perimeter of cluster bezel and remove bezel.
3) Open glove box. Holding glove box door, push center of
glove box bin towards front of vehicle. Flex glove box bin far enough
so glove box stops will clear sides of instrument panel opening. Roll
glove box down until stop bumpers are beyond sides of instrument panel
opening. Release bin. Lift bottom of glove box upward to disengage
hinge hooks form hinge pins.
4) Reach through glove box opening to access and disconnect 2
passenger-side air bag disarm switch harness connectors. Connectors
are attached to bracket located on inboard glove box opening
reinforcement. See Fig. 4. Remove 3 screws retaining passenger-side
air bag disarm switch bezel to instrument panel.