engine DODGE RAM 1999 Service Repair Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 822 of 1691
complete cooling system. Test components as follows, following tool
manufacturer's instructions.
Radiator Cap
Visually inspect radiator cap, then dip cap into water and
connect to tester. Pump tester to bring pressure to upper limit of cap
specification. If cap fails to hold pressure, replace cap.
Fig. 2: Testing Radiator Pressure Cap
Cooling System
1) With engine off, wipe radiator filler neck seat clean.
Fill radiator to correct level. Attach tester to radiator and pump
until pressure is at upper level of radiator rating.
2) If pressure drops, inspect for external leaks. If no leaks
are apparent, detach tester and run engine until normal operating
temperature is reached. Reattach tester and observe. If pressure
builds up immediately, a possible leak exists from a faulty head
gasket or crack in head or block.
NOTE: Pressure may build up quickly. Release any excess pressure
or cooling system damage may result.
3) If there is no immediate pressure build up, pump tester to
within system pressure range (on radiator cap). Vibration of gauge
pointer indicates compression or combustion leak into cooling system.
Isolate leak by shorting each spark plug wire to cylinder block. Gauge
pointer should stop or decrease vibration when leaking cylinder is
shorted.
Page 824 of 1691
pointer is at one o'clock position. Push in on knob slightly and
continue rotating knob to its full clockwise stop. Place knob pointer
at a position about .32" (8 mm) beyond end of Red stripe. Release
knob. If knob is pointing at about .32" (8 mm) beyond end of Red
stripe, go to next step. If knob is not pointing at about .32" (8 mm)
beyond end of Red stripe, go back to step 2) and repeat adjustment
procedure.
4) Rotate temperature control knob counterclockwise so that
knob pointer is at 12 o'clock position. Push temperature control knob
straight into heater control panel until perimeter of knob (not knob
pointer) is flush with base of 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
under REMOVAL & INSTALLATION. If knob does not springs back,
temperature control cable adjustment is complete.
TROUBLE SHOOTING
HEATER PERFORMANCE
Check cooling system. Check serpentine drive belt tension.
Check radiator and radiator fan operation. Ensure that accessory
vacuum supply line is connected at power brake booster (Dakota) or
engine vacuum source (except Dakota).
TESTING
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.
BLOWER MOTOR RELAYS
1) Blower motor relay is located in Power Distribution Center
(PDC). On Ram Van/Wagon, high speed blower motor relay is located in
engine compartment (on side of heater assembly). On all models,
disconnect negative battery cable. Remove blower motor relay. Using an
ohmmeter, check for continuity between terminals No. 87A and 30 of
relay. See Fig. 1. If continuity does not exist, replace relay. If
continuity exists, go to next step.
2) 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.
3) 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.
4) Using jumper wires, connect battery voltage to terminal
No. 86 and ground terminal No. 85. See Fig. 1. 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 blower motor relay. If continuity is as specified,
relay is okay.
Page 828 of 1691
1) Connect a vacuum gauge in line with Black heater vacuum
supply hose (located at tee near power brake booster, in engine
compartment). Position gauge so it can be viewed from passenger
compartment.
2) Start engine. While observing vacuum gauge, rotate mode
control knob to each mode position (one position at a time). Pause
after each selection. Vacuum gauge should drop then return to 8 in. Hg
shortly after each selection is made. If vacuum gauge reading is as
specified, go to next step. If gauge reading is not as specified,
check for vacuum leak in vacuum lines or 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. If temperature control knob does
not operate as specified, check condition, routing, installation and
adjustment of temperature control cable. See
TEMPERATURE CONTROL CABLE ADJUSTMENT.
HEATER OUTPUT
1) Start engine. Allow engine to reach normal operating
temperature. With engine at idle, set controls to maximum heat, floor
and high blower positions. Using a thermometer, check air temperature
coming from floor vents. See HEATER OUTPUT TEMPERATURE table.
2) If floor outlet air temperature is lower than specified,
check cooling system and electric cooling fan. See ELECTRIC COOLING
FAN article.
3) Check that both return and supply heater hoses are hot. If
coolant return hose is much cooler than supply hose, repair coolant
obstruction in heater system. Check for air flow obstruction in heater
system. Check blend air door for proper operation.
HEATER OUTPUT TEMPERATURE
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Ambient Temp. F (C) Outlet Vent Temp. F (C)
Except Durango
60 (15.6) ............................................. 144 (62.2\
)
70 (21.1) ............................................. 147 (63.8\
)
80 (26.6) ............................................. 150 (65.5\
)
90 (32.2) ............................................. 153 (67.2\
)
Durango
60 (15.6) ............................................. 126 (52.2\
)
70 (21.1) ............................................. 133 (56.1\
)
80 (26.6) ............................................. 139 (59.4\
)
90 (32.2) ............................................. 144 (62.2\
)
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REMOVAL & INSTALLATION
* 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.
BLEND AIR DOOR MOTOR
Removal & Installation (Ram Pickup)
Remove heater assembly. See HEATER ASSEMBLY. Remove blend air
Page 829 of 1691
door servo motor electrical connector and mounting bolts. Remove blend
air door servo motor. Ensure blend air door operates properly without
restriction or binding. To install, reverse removal procedure.
Removal & Installation (Ram Van/Wagon)
Disconnect negative battery cable. Remove glove box.
Disconnect wire harness connector from blend air door motor.
Disconnect blend air door motor lever and remove link from retainer.
Remove 3 mounting bolts and remove blend air door motor.
BLOWER MOTOR
Removal (Dakota & Durango)
1) Disconnect negative battery cable. Remove and disassemble
heater assembly. See HEATER ASSEMBLY. Disconnect blower motor lead at
bottom of housing. Remove 6 bolts and blower motor housing cover.
2) Remove blower motor and fan assembly. Place reference
marks on blower motor and fan for installation reference. Remove
blower fan retainer clip. Pull blower motor fan off blower motor
shaft.
Installation
Align reference marks made during removal. Press blower fan
hub onto blower motor shaft. Ensure retainer clip ears are indexed
over flats of blower motor shaft and fan hub. To complete
installation, reverse removal procedure.
Removal (Ram Pickup)
1) Blower motor is located under glove box and can be removed
from passenger compartment. See Fig. 5. Disconnect negative battery
cable. Disconnect blower motor cooling tube. Remove blower motor
electrical connector from retainer. Disconnect electrical connector.
2) Remove blower motor and fan assembly mounting bolts.
Remove blower motor and fan assembly. Place reference marks on blower
motor and fan for installation reference. Remove blower motor fan
retainer clip. Pull blower motor fan off blower motor shaft.
Installation
Align reference marks made during removal. Press blower fan
hub onto blower motor shaft. Ensure retainer clip ears are indexed
over flats of blower motor shaft and fan hub. Ensure blower motor seal
is installed on housing. To complete installation, reverse removal
procedure.
Removal (Ram Van/Wagon)
1) Disconnect negative battery cable. Remove top half of
radiator shroud. At right side of engine compartment, disconnect
blower motor wiring connector and motor cooling tube. Remove nuts and
washers from blower motor backing plate to heater housing studs. See
Fig. 6 .
2) Remove blower motor assembly. Place reference marks on
blower motor and fan for installation reference. Remove blower motor
fan retainer clip. Pull blower motor fan off blower motor shaft.
Inspect backing plate seal for breaks and adhesion.
Installation
Align reference marks made during removal. Press blower fan
hub onto blower motor shaft. Ensure retainer clip ears are indexed
over flats of blower motor shaft and fan hub. Apply a small bead of
rubber sealant to blower motor side of rubber seal. To complete
installation, reverse removal procedure.
Page 831 of 1691
Fig. 6: Identifying Heater Assembly Components (Ram Van/Wagon)
Courtesy of Chrysler Corp.
BLOWER MOTOR RESISTOR
Removal & Installation (Dakota & Durango)
Blower motor resistor is located in engine compartment, under
upper right corner of dash panel. Disconnect negative battery cable.
Remove cowl plenum cover to access resistor. Remove blower motor
resistor connector. Remove resistor retaining bolts. Remove blower
motor resistor. To install, reverse removal procedure.
Removal & Installation (Ram Pickup)
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
bolts. Remove blower motor resistor. To install, reverse removal
procedure.
Removal & Installation (Ram Van/Wagon)
Blower motor resistor is located behind glove box, attached
to dash plenum panel. Disconnect negative battery cable. Remove glove
box bin. Disconnect blower motor resistor connector. Remove resistor
retaining bolts. Remove blower motor resistor. To install, reverse
Page 832 of 1691
removal procedure.
HEATER ASSEMBLY
Removal (Dakota & Durango)
1) Disconnect negative battery cable. Drain cooling system.
Remove instrument panel. See INSTRUMENT PANEL.
2) In engine compartment, disconnect heater hoses and plug
all openings. Remove 4 heater assembly nuts from engine compartment
firewall. Inside vehicle, remove heater assembly support brace screw,
and swing support brace out of way. Move passenger seat rearward.
3) Carefully pull heater assembly rearward until studs and
heater core tubes clear firewall. Lower heater assembly and rotate
assembly until studs are facing downward. Remove heater assembly from
vehicle.
4) Place heater assembly on work bench with assembly housing
cover facing down. Remove 2 bolts securing heater assembly housing
cover to blower motor housing cover. Unplug vacuum harness connector
from panel/defrost door actuator.
5) Remove floor duct from heater assembly housing. Remove 2
bolts securing heater assembly housing cover to lower housing near
floor outlet. Turn assembly over. Disengage vacuum harness retainer
and vacuum harness. Remove 13 screws securing housing cover.
6) Remove blend-air door lever. Gently pry panel-defrost door
lever off. Pull up on heater assembly housing cover far enough to
separate cover sealant and remove cover.
Installation
Ensure blower motor housing cover sealant is in place and in
good condition. To complete installation, reverse removal procedure.
Removal (Ram Pickup)
1) Disconnect negative battery cable. Drain cooling system.
In engine compartment, remove coolant hoses from heater core tubes.
Plug all openings. Remove coolant overflow bottle. Remove instrument
panel. See INSTRUMENT PANEL . Remove Powertrain Control Module (PCM)
and position aside. DO NOT disconnect 60-pin connector from PCM.
2) 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 heater assembly from vehicle.
3) Place heater assembly upside-down on work bench. Remove
screw securing floor duct to bottom of heater assembly and slide floor
duct off of center heat duct adapter. Unsnap center heat duct adapter
from bottom of heater assembly housing. Remove screw hidden behind
adapter. Remove remaining screws and separate heater assembly.
Installation
Ensure mode door pivot pins are properly inserted in holes.
To complete installation, reverse removal procedure.
Removal & Installation (Ram Van/Wagon)
1) Disconnect negative battery cable. Drain engine cooling
system. In engine compartment, protect generator from coolant
spillage. Remove heater hoses from heater core tubes. Plug all
openings. Remove grille, cowl grille support panel, right headlight
assembly, and right radiator core support assembly. See Fig. 7.
2) From inside vehicle, remove glove box bin. Through glove
box opening and from under instrument panel, remove nuts and bolts
attaching heater assembly to dash panel.
3) Remove blower housing flange screws. Separate heater
assembly from blower housing. See Fig. 6. Carefully remove heater
assembly from vehicle.
Page 834 of 1691
side of instrument panel, near transmission tunnel, and unplug heater
control panel-to-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. 8. Carefully pry bezel away from instrument
panel to disengage clips. Unplug connectors from cigarette lighter and
auxiliary power outlet.
4) Remove 4 bolts attaching heater control panel. Pull
control panel outward enough to disconnect wiring connector and vacuum
harness. Remove heater control panel. To install, reverse removal
procedure.
Fig. 8: Removing Cluster Bezel (Ram Pickup)
Courtesy of Chrysler Corp.
CAUTION: Use care when removing or installing instrument cluster bezel
so as not to damage trip odometer reset button. If trip
odometer reset button is damaged, instrument cluster must be
replaced.
Removal & Installation (Ram Van/Wagon)
1) Disconnect negative battery cable. Remove engine cover
from passenger compartment. Reach between upper dash panel engine
housing extension and bottom of instrument panel. Disconnect vacuum
harness connector located near left defroster outlet of distribution
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. Carefully pry
bezel away from instrument panel to disengage clips. Pull bezel away
far enough to clear trip odometer reset button. Remove bezel.
3) Remove 3 bolts from heater control panel. Pull heater
control panel outward enough to disconnect electrical connectors and
Page 838 of 1691
Removal (Dakota, Durango & Ram Pickup)
1) Vacuum reservoir is located in engine compartment, under
cowl plenum cover. Disconnect negative battery cable. With hood open,
unsnap and remove wiper arm pivot cover. Remove wiper arm nut. Mark
wiper arm and pivot for installation reference. Using battery terminal
puller, remove wiper arms.
2) Remove weatherstrip along front edge of cowl plenum cover
and cowl plenum panel. Remove plastic nuts, plastic rivets, and
plastic push-in retainers from cowl plenum cover. Unsnap slotted
center hole from adhesive backed snap fastener. Ensure not to remove
fastener from cowl side panel.
3) Lift cowl plenum cover enough to access windshield washer
nozzle and vacuum plumbing. Disconnect vacuum supply hose from vacuum
reservoir. Remove cowl plenum cover. Remove bolts and vacuum
reservoir.
Installation
To install, reverse removal procedure. Ensure all hoses are
clear and not pinched. Tighten wiper arm nuts to specification. See
TORQUE SPECIFICATIONS .
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)\
Wiper Arm Nuts (Dakota & Pickup) ........................... 18 (24\
)
Steering Column Toe Plate Nuts (Pickup) .................... 17 (23\
)
INCH Lbs. (N.m)
ACM Mounting Bolts ......................................... 97 (11)\
Instrument Panel
Pivot Bolts ............................................. 106 (12)\
Upper Mounting Screws ................................... 28 (3.2)\
Steering Column
Bracket Nuts ............................................ 106 (12)\
Multifunction Switch Connector Screw ...................... 18 (2)\
Shroud Screws ............................................. 18 (2)\
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VACUUM DIAGRAMS
Page 849 of 1691
WIRING DIAGRAM COMPONENT LOCATIONS
When trying to locate a component in a wiring diagram and you
don't know the specific system where it is located, use this handy
component locator to find the system wiring diagram in which the
component is located. Then, go to that system and locate the component
within the wiring diagram.
For example, if you don't know the specific system in which
the ignition switch is located, look up ignition switch in the wiring
diagram component location tables and go to the appropriate wiring
diagram(s) which contain either full or partial views of the ignition
switch. The full view of the ignition switch is located in Power
Distribution.
The first listing for the component will be the full or most
complete view of the component. Additional listings will be partial
views of the component. Not all components are used on all models.
All components will have a partial view in Ground
Distribution and Power Distribution. Data Link Connectors show
connecting circuits between modules. Alternate names for components
may be listed in wiring diagram component locations tables.
WIRING DIAGRAM COMPONENT LOCATIONS TABLE
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Component Wiring Diagram
ABS Electronic Control Unit ....................... Anti-Lock Brakes
Data Link Connectors
ABS Hydraulic Unit ................................ Anti-Lock Brakes
Acceleration Sensor ............................... Anti-Lock Brakes
Accessory Delay Relay ................................ Power Windows
A/C Compressor Clutch Relay ..................... Engine Performance
A/C Sensor ...................................... Engine Performance
A/C Pressure Switch ............................. Engine Performance
Adaptive Lamp Control Module ....................... Exterior Lights
Air Bag(s) ................................ Air Bag Restraint System\
Air Bag Module ............................ Air Bag Restraint System
Air Bag Sensor(s) ......................... Air Bag Restraint System\
Air Injection Pump Relay ........................ Engine Performance
Air Temperature Sensor ............................ Overhead Console
Alternator (Generator) ..................... Generators & Regulators\
Anti-Theft Control Module ........................ Anti-Theft System
Starters
Autolamp Control Relay ........................... Headlight Systems
Daytime Running Lights
Automatic Shutdown (ASD) Relay .................. Engine Performance\
Generators & Regulators
Autostick Switch ................................ Engine Performance
Auxiliary Battery Relay .................... Generators & Regulators
Back-Up Lights ...................................... Back-Up Lights
Exterior Lights
Barometric (BARO) Pressure Sensor ............... Engine Performance\
Battery ......................................... Power Distribution
Battery Temperature Sensor ...................... Engine Performance
Body Control Module .......................... Body Control Computer
Anti-Theft System
Daytime Running Lights
Engine Performance
Headlight Systems
Warning Systems
Boost Control Solenoid .......................... Engine Performance
Boost Sensor .................................... Engine Performance
Brake Fluid Level Switch .................. Analog Instrument Panels
Page 850 of 1691
![DODGE RAM 1999 Service Repair Manual Brake On/Off (BOO) Switch ................... Cruise Control Systems\
Engine Performance
Shift Int](/img/12/56915/w960_56915-849.png "DODGE RAM 1999 Service Repair Manual Brake On/Off (BOO) Switch ................... Cruise Control Systems\
Engine Performance
Shift Int")
Brake On/Off (BOO) Switch ................... Cruise Control Systems\
Engine Performance
Shift Interlock Systems
Buzzer Module ...................................... Warning Systems
Camshaft Position (CMP) Sensor .................. Engine Performance\
Central Control Module ........................... Anti-Theft System
Clockspring ............................... Air Bag Restraint System
Cruise Control Systems
Steering Column Switches
Clutch Pedal Position Switch .............................. Starters
Clutch Start Switch ....................................... Starters
Combination Meter ......................... Analog Instrument Panels
Constant Control Relay Module (CCRM) ............ Engine Performance\
Electric Cooling Fans
Convenience Center .............................. Power Distribution
Illumination/Interior Lights
Convertible Top Motor ........................ Power Convertible Top
Convertible Top Switch ....................... Power Convertible Top
Crankshaft Position (CKP) Sensor ................ Engine Performance\
Cruise Control Module ....................... Cruise Control Systems
Cruise Control Switch ....................... Cruise Control Systems
Condenser Fan Relay(s) ....................... Electric Cooling Fans\
Data Link Connector (DLC) ....................... Engine Performance\
Daytime Running Lights Module ............... Daytime Running Lights
Exterior Lights
Defogger Relay ................................ Rear Window Defogger
Diagnostic Energy Reserve Module (DERM) ... Air Bag Restraint System\
Discriminating Sensor (Air Bag) ........... Air Bag Restraint System\
Distributor ..................................... Engine Performance
Door Lock Actuators ............................... Power Door Locks
Remote Keyless Entry
Door Lock Relay(s) ................................ Power Door Locks\
Electrochromic Mirror ................................ Power Mirrors
Electronic Level Control (ELC)
Height Sensor .............................. Electronic Suspension
Electronic Level Control (ELC) Module ........ Electronic Suspension\
Engine Coolant Temperature (ECT)
Sending Unit ............................ Analog Instrument Panels
Engine Coolant Temperature (ECT) Sensor ......... Engine Performance\
Engine Control Module ........................... Engine Performance
Generators & Regulators
Starters
ETACS ECU .......................................... Warning Systems
Power Windows
Remote Keyless Entry
Evaporative (EVAP) Emissions Canister ........... Engine Performance\
EVAP Canister Purge Solenoid .................... Engine Performance
EVAP Canister Vent Solenoid ..................... Engine Performance
Exhaust Gas Recirculation (EGR) Valve ........... Engine Performance\
Fuel Tank Vacuum Sensor ......................... Engine Performance
Fog Lights ....................................... Headlight Systems
Daytime Running Lights
Fog Light Relay .................................. Headlight Systems
Daytime Running Lights
Fuel Door Release Solenoid ................. Power Fuel Door Release
Fuel Gauge Sending Unit ................... Analog Instrument Panels
Fuel Injectors .................................. Engine Performance
Fuel Pump ....................................... Engine Performance
Fuel Pump Relay ................................. Engine Performance
Power Distribution
Fuse/Relay Block ................................ Power Distribution
Fusible Links ................................... Power Distribution
Generators & Regulators