tow DODGE RAM 1999 Service User Guide
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 54 of 1691
are continually republished. In addition to these, standards for Drive
Train and Transmissions have recently been promulgated. Participating
shops utilize these Uniform Inspection & Communication Standards as
part of the inspection process and for communicating their findings to
their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not
satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-
profit organizations. MAP conducted pilot programs in twelve states
before announcing the program nationally in October, 1998. During the
pilots, participating repair shops demonstrated their adherence to the
Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some
"teeth" in the program, an accreditation requirement for shops was
initiated. The requirements are stringent, and a self-policing method
has been incorporated which includes the "mystery shopping" of
outlets.
We welcome you to join us as we continue our outreach... with
your support, both the automotive repair industry and your customers
will reap the benefits. Please visit MAP at our Internet site www.
motorist.org or contact us at:
1444 I Street, NW Suite 700
Washington, DC 20005
Phone (202) 712-9042 Fax (202) 216-9646
January 1999
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
It is MAP policy that all exhaust, brake, steering,
suspension, wheel alignment, drive-line, engine performance and
maintenance, and heating, ventilation and air conditioning, and
electrical services be offered and performed under the standards and
procedures specified in these sections.
Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be "Required" or
"Suggested". In addition, suggestions may be made to satisfy the
requests expressed by the customer.
When a component is suggested or required to be repaired or
replaced, the decision to repair or replace must be made in the
customer's best interest, and at his or her choice given the options
available.
This section lists the various parts and conditions that
indicate a required or suggested service or part replacement.
Although this list is extensive, it is not fully inclusive. In
addition to this list, a technician may make a suggestion. However,
any suggestions must be based on substantial and informed experience,
Page 104 of 1691
assembly towards right side of vehicle and remove rear A/C-heater
assembly.
5) To install, reverse removal procedure. Ensure all wiring
and hoses are clear and not pinched. Tighten bolts and nuts to
specification. See TORQUE SPECIFICATIONS .
Removal (Ram Pickup - Front)
1) Disconnect negative battery cable. Drain cooling system.
In engine compartment, remove coolant hoses from heater core tubes.
Remove coolant overflow bottle.
2) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Disconnect refrigerant lines from
evaporator and plug or cover all openings in A/C system. Remove
instrument panel. See INSTRUMENT PANEL. Remove Powertrain Control
Module (PCM) and position aside. DO NOT disconnect 60-pin connector
from PCM.
3) Remove attaching nuts from studs on engine compartment
side of dash panel. Remove defrost duct. Disconnect electrical
connectors. Remove attaching nuts from studs in passenger compartment
side of dash panel. Remove A/C-heater assembly from vehicle. See
Fig. 5 .
4) Place A/C-heater assembly upside-down on work bench.
Remove screw securing floor duct to bottom of A/C-heater assembly and
slide floor duct off of center heat duct adapter. Unsnap center heat
duct adapter from bottom of A/C-heater assembly housing. Remove screw
hidden behind adapter. Remove remaining screws and separate A/C-heater
assembly.
Installation
Ensure mode door pivot pins are properly inserted in holes.
To complete installation, reverse removal procedure.
A/C-HEATER CONTROL PANEL R & I
Removal & Installation (Dakota & Durango)
1) Disconnect negative battery cable. On models equipped with
A/T, unlock ignition switch. Set parking brake and place gear selector
lever in "L" position. If equipped, set tilt steering column in lowest
position.
2) On all models, carefully pry bezel away from instrument
panel to disengage clips. Unplug connectors from cigarette lighter and
auxiliary power outlet. Disconnect fog light switch (if equipped).
Remove A/C-heater control panel screws.
3) Pull control panel outward enough to disconnect wiring
connector, vacuum harness, and temperature control cable. Remove A/C-
heater control panel. To install, reverse removal procedure. Adjust
temperature control cable. See TEMPERATURE CONTROL CABLE ADJUSTMENT .
Removal & Installation (Ram Pickup)
1) Disconnect negative battery cable. Reach under driver's
side of instrument panel, near transmission tunnel and unplug A/C-
heater control panel to A/C-heater assembly vacuum harness connector.
Disconnect vacuum harness from center air duct.
2) On models equipped with A/T, unlock ignition switch. Set
parking brake and place gear selector lever in "L" position. If
equipped, set tilt steering column in lowest position.
3) On all models, remove screw securing cluster bezel to
instrument panel. See Fig. 6. Carefully pry bezel away from instrument
panel to disengage clips. Unplug connectors from cigarette lighter and
auxiliary power outlet.
4) Remove 4 screws attaching A/C-heater control panel. Pull
control panel outward enough to disconnect wiring connector, vacuum
harness and temperature control cable. Remove A/C-heater control
Page 107 of 1691
install, reverse removal procedure.
Removal & Installation (Ram Pickup - Front)
Blower motor resistor is located under glove box, attached to
blower motor housing. See Fig. 5. Disconnect negative battery cable.
Remove blower motor resistor connector. Remove resistor retaining
screws. Remove blower motor resistor. To install, reverse removal
procedure.
BLOWER MOTOR SWITCH (REAR)
Removal & Installation (Durango)
Disconnect negative battery cable. Pry above indentations at
outer perimeter of rear blower motor switch. Pull rear blower motor
switch and disconnect electrical connector. Remove rear blower motor
switch. To install, reverse removal procedure.
COMPRESSOR
Removal & Installation
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
refrigerant lines and plug or cover all openings in A/C system.
2) Remove drive belt. Disconnect compressor electrical leads.
Remove compressor mounting nuts and bolts. Remove compressor. Drain
oil from compressor, and record amount of oil drained.
3) To install, reverse removal procedure. Using new
refrigerant oil, add to compressor the same amount of oil drained from
it. Evacuate and charge A/C system.
CONDENSER
NOTE: Before removing condenser, note location of radiator and
condenser air seals. If air seals are not installed properly,
A/C and engine cooling systems will not perform properly.
Removal
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
A/C fittings at inlet and outlet of condenser. Plug or cover all
openings in A/C system.
2) On Dakota, remove bolts securing radiator and fan shroud
to inside of upper radiator crossmember. Remove top mounting bolts
securing condenser to upper crossmember. Tilt top of radiator and fan
shroud toward engine.
3) On Ram Pickup (gasoline engine), remove bolts securing
condenser upper mounting brackets to outside of upper radiator
crossmember. Tilt condenser away from engine compartment far enough to
grasp top of condenser with both hands. On Ram Pickup (diesel engine),\
remove bolts securing condenser to charge air cooler. On all models,
lift condenser assembly from vehicle.
Installation
To install, reverse removal procedure. Install new "O" rings
to fittings. Fill cooling system. Evacuate and charge A/C system.
EVAPORATOR CORE & HEATER CORE
Removal & Installation (Dakota & Durango - Front)
Remove instrument panel. See INSTRUMENT PANEL. Remove A/C-
heater assembly. See A/C-HEATER ASSEMBLY. With A/C-heater housing
removed, remove housing cover. Remove evaporator core or heater core
Page 118 of 1691
A/C -H EA TE R S YSTE M T R O UBLE S H O OTIN G
1999 D odge P ic ku p R 1500
1999 MANUAL A/C-HEATER SYSTEMS
Trouble Shooting - Cars & Trucks
CHRYSLER
Avenger, Breeze, Caravan, Cirrus, Concorde, Dakota, Durango,
Intrepid, LHS, Neon, Ram Pickup, Ram Van/Wagon, Sebring Convertible,
Sebring Coupe, Stratus, Town & Country, Voyager, 300M
A/C SYSTEM DIAGNOSIS
RAPID COMPRESSOR CLUTCH CYCLING
Some possible causes of rapid compressor clutch cycling,
clutch cycles 10 or more times per minute, include:
* Low refrigerant system charge.
* Faulty low pressure cycling clutch switch.
* Faulty PCM.
COMPRESSOR WILL NOT ENGAGE
Some possible causes of compressor not engaging with high and
low side system pressures equal include:
* No refrigerant in system.
* Faulty fuse.
* Faulty compressor clutch coil.
* Faulty compressor clutch relay.
* Faulty electronic cycling clutch switch.
* Improperly installed or faulty low pressure cycling clutch
switch.
* Faulty low pressure cut-off switch.
* Faulty high pressure cut-off switch.
* Faulty PCM.
* Faulty A/C-heater control panel.
TEMPERATURE IS TOO HIGH WITH A/C ON
Some possible causes of high temperature output at center
panel when A/C system pressure is normal include:
* Excessive oil charge in refrigerant.
* Temperature control cable improperly installed or faulty.
* Blend-air door inoperative, obstructed or sealing
improperly.
* Blend door actuator not calibrated.
LOW SIDE PRESSURE IS LOW-TO-NORMAL & HIGH SIDE PRESSURE IS
LOW
Some possible causes of low side system pressure being lower-
to-normal and high side system pressure being too low include:
* Low refrigerant system charge.
* Refrigerant flow through accumulator is restricted.
* Refrigerant flow through evaporator is restricted.
* Faulty compressor.
LOW SIDE PRESSURE IS HIGH-TO-NORMAL & HIGH SIDE PRESSURE IS
Page 133 of 1691
SERVICE VALVE LOCATIONS
For service valve locations, see SERVICE VALVE LOCATIONS
(CARS) or SERVICE VALVE LOCATIONS (TRUCKS & VANS) table.
SERVICE VALVE LOCATIONS (CARS)
\
\
\
\
\
\
\
Vehicle High Low
Chrysler Corp.
Avenger & Sebring Coupe .................... ( 1) ........... ( 2)
Concorde, Intrepid, LHS & 300M
2.7L ...................................... ( 3) ........... ( 4)
3.2L & 3.5L ............................... ( 5) ........... ( 6)
Breeze, Cirrus & Stratus ................... ( 7) ........... ( 4)
Neon ....................................... ( 7) ........... ( 4)
Sebring Convertible ........................ ( 7) ........... ( 4)
Ford Motor Co.
Continental ................................ ( 9) .......... ( 10)
Contour, Cougar & Mystique
2.0L Engine ............................... ( 7) .......... ( 11)
2.5L Engine ............................... ( 7) .......... ( 12)
Crown Victoria, Grand Marquis & Town Car ... ( 7) .......... ( 13)
Escort & Tracer ............................ ( 14) ......... ( 10)
Mustang .................................... ( 7) .......... ( 12)
Sable & Taurus ............................. ( 8) .......... ( 11)
General Motors
"C" Body ................................... ( 3) .......... ( 15)
"E" & "K" Bodies ........................... ( 3) .......... ( 15)
"F" Body ................................... ( 9) ........... ( 4)
"G" Body ................................... ( 3) .......... ( 15)
"H" Body ................................... ( 7) .......... ( 12)
"J" Body ................................... ( 7) .......... ( 12)
"M" Body ................................... ( 9) ........... ( 4)
"N" Body ................................... ( 9) ........... ( 4)
"S" Body ................................... ( 9) ........... ( 4)
"V" Body ................................... ( 9) ........... ( 4)
"W" Body ................................... ( 9) ........... ( 4)
"Y" Body ................................... ( 3) .......... ( 12)
"Z" Body ................................... ( 7) .......... ( 15)
( 1) - On high-side liquid line, between receiver-drier and evaporator.
( 2) - On low-side hose between evaporator and compressor.
( 3) - On high-side liquid line.
( 4) - On low-side suction line.
( 5) - On top of compressor manifold.
( 6) - On compressor manifold, closest to compressor clutch.
( 7) - On high-side line, between compressor and condenser.
( 8) - On extension of high-side line, between condenser and
evaporator.
( 9) - On high-side line (or extension), near condenser.
( 10 ) - On low-side line (or extension), near accumulator.
( 11 ) - On low-side line, between the evaporator and
accumulator/receiver-drier.
( 12 ) - On low-side line, between acumulator/receiver-dryer and
compressor.
( 13 ) - On acumulator/receiver-drier.
( 14 ) - On high-side line, near condenser.
( 15 ) - On low-side line, between orifice tube and evaporator.
\
\
\
\
\
\
\
SERVICE VALVE LOCATIONS (TRUCKS & VANS)
Page 134 of 1691
![DODGE RAM 1999 Service User Guide \
\
\
\
\
\
\
Vehicle](/img/12/56915/w960_56915-133.png "DODGE RAM 1999 Service User Guide \
\
\
\
\
\
\
Vehicle")
\
\
\
\
\
\
\
Vehicle High Low
Chrysler Corp.
Caravan, Town & Country, & Voyager ......... (1) ........... ( 2)
Dakota ..................................... ( 3) ........... ( 4)
Durango .................................... ( 3) ........... ( 4)
Ram Pickup ................................. ( 3) ........... ( 5)
Ram Van/Wagon .............................. ( 6) ........... ( 7)
Ford Motor Co.
"E" Series ................................. ( 4) ........... ( 8)
Explorer, Mountaineer & Ranger ............. ( 6) ........... ( 9)
F150, F250LD, Expedition & Navigator ....... ( 6) ........... ( 9)
F250HD, F350 & Super Duty .................. ( 6) ........... ( 5)
Villager ................................... ( 10) .......... ( 5)
Windstar ................................... ( 11) .......... ( 9)
General Motors
"C" & "K" Series ........................... ( 4) ........... ( 9)
"G" Series ................................. ( 12) .......... ( 9)
"J" Series ................................. ( 9) .......... ( 13)
"L" & "M" Series ........................... ( 12) .......... ( 5)
"P" Series ................................. ( 14) ......... ( 15)
"S" & "T" Serie ............................ ( 16) .......... ( 9)
"U" Series ................................. ( 1) ........... ( 5)
Jeep
Cherokee ................................... ( 6) .......... ( 17)
Grand Cherokee ............................. ( 18) ......... ( 14)
Wrangler ................................... ( 4) .......... ( 14)
( 1) - On high-side line, near right frame rail. See Fig. 7.
( 2) - On low-side line, near compressor. See Fig. 7.
( 3) - On high-side line, between condenser and evaporator, near front
of engine compartment.
( 4) - On compressor manifold.
( 5) - On low-side line, near accumulator.
( 6) - On high-side line, between compressor and condenser, near front
of engine compartment.
( 7) - On low-side line extension, near receiver-drier, at front of
engine compartment.
( 8) - On low-side line from accumulator, near windshield washer
reservoir.
( 9) - On accumulator/receiver-drier.
( 10 ) - On high-side line extension from compressor.
( 11 ) - On high-side line, between compressor and condenser, near
accumulator. See Fig. 8.
( 12 ) - On high-side line between evaporator and condenser, near
evaporator.
( 13 ) - On low-side (suction) line, near compressor.
( 14 ) - On high-side inlet line, at evaporator.
( 15 ) - On low-side outlet line, at evaporator.
( 16 ) - On high-side line.
( 17 ) - On low-side (suction) line, between accumulator outlet and
compressor.
( 18 ) - On high-side (liquid) line, near evaporator inlet, at rear of
engine compartment.
\
\
\
\
\
\
\
Page 135 of 1691
Fig. 7: Locating Service Valves (Caravan, Town & Country, & Voyager)
Courtesy of chrysler corp.
Page 138 of 1691
2) Ensure service hoses are equipped with valve core
depressor to match Schrader valve. If not, install special adapters
for this purpose. If the high-side service hose connector will not fit
on high-side Schrader valve, a special adapter must be used. See
SPECIAL VALVE CONNECTORS.
3) Ensure both manifold gauge set hand valves are closed.
Connect low-side service hose to low-side (suction) service valve, and\
finger tighten connections. Connect high-side service hose to high-
side (discharge) service valve, and finger-tighten connections.
NOTE: After test gauges are installed, test hoses must be purged of
all air before proceeding with testing.
PURGING TEST HOSES
1) Ensure high-side and low-side hoses are properly connected
to service valves, and all hose connections are tight. Place a clean
shop towel over end of center service hose.
2) Purge high-side test hose by opening hand valve on high-
side gauge for 3-5 seconds. This allows the system's refrigerant to
force air through test hoses and out of center service hose into the
shop towel. Immediately close high-side gauge hand valve.
3) Purge low-side test hose in the same manner using hand
valve of low-side gauge. Close hand valve after 3-5 seconds. Purging
of test hoses is now complete, and system is ready for testing.
NOTE: If manifold gauge set is to be used in conjunction with
refrigerant recovery/recycling equipment, use instructions
provided with the recovery/recycling equipment to properly
purge test hoses.
STABILIZING A/C SYSTEM
1) Once manifold gauge set is attached to system and test
hoses have been purged, the system is ready for testing. Place all
test hoses, gauge set and other equipment away from all moving parts
of engine.
2) Start engine, and turn A/C controls to maximum cooling
position (full cold or MAX A/C). Set blower on high speed. Open doors
and/or windows. Operate system for 5-10 minutes. System should now be
stabilized and ready for test readings.
PRESSURE-TEMPERATURE RELATIONSHIP
A refrigerant, when confined in an enclosed space, increases
in pressure as the temperature increases. Conversely, if the
temperature is lowered, the pressure also decreases.
Depending on temperature, a corresponding pressure will exist
in such an enclosed space. For example, at 70
F (21.1 C) a gauge will
indicate about 71.0 psi (5.0 kg/cm). The R-134a PRESSURE- TEMPERATURE
RELATIONSHIP table shows this relationship.
R-134a PRESSURE-TEMPERATURE RELATIONSHIP
\
\
\
\
\
\
\
Temperature F ( C) ( 1) psi (kg/cm)
20 (-6.7) ................................................. 18 (1.3\
)
30 (-1.1) ................................................. 26 (1.8\
)
40 (4.4) .................................................. 35 (2.5\
)
50 (10.0) ................................................. 45 (3.2\
)
60 (15.6) ................................................. 57 (4.0\
)
Page 145 of 1691
ORIFICE TUBE REPLACEMENT
CHRYSLER CORP.
Removal & Installation (Dakota)
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
liquid line at condenser outlet tube. Cover open refrigerant fittings
to protect from moisture and dirt.
2) Using 2 wrenches, loosen tube fitting and separate front
half of liquid line from rear half of liquid line. Using needle nose
pliers, remove fixed orifice tube from rear half of liquid line. Note
fixed orifice tube orientation for correct installation.
3) To install, reverse removal procedure. Ensure fixed
orifice tube is positioned correctly. Evacuate, charge, and leak test
A/C system. Ensure A/C system operates properly.
NOTE: On Ram Pickup, if the fixed orifice tube is faulty or
plugged, the liquid line and orifice tube must be replaced as
an assembly.
Removal & Installation (Ram Pickup)
Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
liquid line from evaporator inlet and condenser outlet tubes. Cover
open refrigerant fittings to protect from moisture and dirt.
Disconnect liquid line retaining clips. Remove liquid line and orifice
tube. To install, reverse removal procedure. Evacuate, charge, and
leak test A/C system. Ensure A/C system operates properly.
FORD MOTOR CO.
NOTE: Replace orifice tube whenever compressor is replaced. Fixed
orifice tube is located in the condenser-to-evaporator liquid
line.
NOTE: DO NOT use pliers to remove fixed orifice tube or twist
orifice tube in liquid line. Doing so will cause plastic
orifice tube body to break inside condenser-to-evaporator
liquid line.
Fixed Orifice Tube Replacement (Except Continental, Mustang &
Villager)
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. On Contour
and Mystique, move power steering fluid reservoir to one side without
disconnecting hoses.
2) On all models, disconnect condenser-to-evaporator
discharge (liquid) line. Remove and discard "O" rings from line. Pour
a small amount of refrigerant oil into inlet to lubricate orifice "O"
rings.
3) Insert orifice tube remover/installer into tube and turn
tool to right to engage tangs on orifice tube. See Fig. 18. Hold "T"
handle of tool and slowly tighten nut down onto discharge line to
slowly pull orifice tube out. If orifice tube breaks off when removal
is attempted, use orifice tube extractor to pull the broken section
out. See Fig. 19.
4) Ensure replacement orifice tube is fitted with "O" ring(s)\
lubricated with clean refrigerant oil. Insert tube with short end
toward evaporator, until seated. Reconnect high pressure line. On
Contour and Mystique, tighten connection to 18 ft. lbs. (24 N.m).
Page 147 of 1691
Fig. 19: Removing Broken Orifice Tube (Typical)
Courtesy of ford motor co.
NOTE: On Continental, Mustang and Villager, if orifice tube is
faulty or plugged, liquid line and orifice tube must be
replaced as an assembly or an orifice tube replacement kit
must be installed.
Orifice Tube Replacement Kit (Continental & Mustang)
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove condenser-to-evaporator liquid
line from vehicle. Locate orifice tube in metal portion of liquid
line, near bend (indented notches or circular depression). See Fig. 20
.
2) Cut a 2.5" (63.5 mm) section from liquid line, at least 1\
"
(25.4 mm) from start of bend in line and discard. Clean out liquid
line to remove contaminants.
3) Lubricate orifice tube replacement kit compression nuts
and rings with refrigerant oil and install on liquid line. See Fig. 21
. Ensure flow direction arrow points toward evaporator. Ensure liquid
line is properly aligned for installation. Tighten compression nuts to
65-69 ft. lbs. (88-94 N.m).
4) To complete installation, reverse removal procedure.
Lubricate "O" rings with refrigerant oil. Evacuate, charge and leak