service DODGE RAM 1999 Service Owner's Guide
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 89 of 1691
Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket holes elongated,
affecting performance .. A .. Require repair or replacement.
Bracket holes elongated,
not affecting
performance ............ .. ........ No service suggested or
required.
Bracket loose, affecting
performance ............ A .. Require repair or replacement.
Bracket loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket missing ......... C ............ Require replacement.
Connection damaged ...... B .. Require repair or replacement.
Contaminated, affecting
performance ............ A ............ Require replacement.
Corroded internally ..... 1 ............ Suggest replacement.
Dessicant bag
deteriorated ........... A ........ (1) Require replacement.
Further inspection required.
Dessicant at the end of
its useful life
(saturated
with moisture) ......... 1 .. Suggest repair or replacement.
Filter screen torn ...... A .. Require replacement of screen.
Fitting damaged ......... B .. Require repair or replacement.
Fusible plug leaking .... A .... Require replacement of plug.
Inoperative ............. A ........... ( 2) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Pressure relief device
leaking ................ A . Require replacement of pressure
relief device.
Restricted .............. A .. Require repair or replacement.
Sight glass no longer
transparent ............ 2 ... Suggest replacement of drier.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Tubing connection
leaking ................ A .. Require repair or replacement.
( 1) - Inspect system to determine effects of dessicant bag
deterioration.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.
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WATER PUMPS (ELECTRIC AUXILIARY)
WATER PUMP (ELECTRIC AUXILIARY) INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Page 92 of 1691
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.
Page 95 of 1691
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
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1) Locate low pressure cut-out switch located on suction
line, near firewall. Ensure system pressure is correct. See
A/C SYSTEM PERFORMANCE test. Disconnect negative battery cable.
Disconnect low pressure cut-out switch connector.
2) Place a jumper wire across terminals of low pressure cut-
out switch harness connector. Connect negative battery cable. Connect
manifold gauge set. Set A/C-heater controls to A/C. Start and operate
engine at idle speed.
3) Using an ohmmeter, check for continuity between switch
terminals. Continuity should exist when suction pressure reading is
between 13-27 psi (.9-1.9 kg/cm
). Continuity should not exist when
suction pressure reading is 10 psi (.7 kg/cm) or lower. If switch is
okay, repair open or short in Brown wire between low pressure cut-out
switch and PCM. If switch is not okay, replace faulty low pressure
cut-out switch.
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.
A/C-HEATER ASSEMBLY
Removal (Dakota & Durango - Front)
1) Disconnect negative battery cable. Drain cooling system.
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 .
2) In engine compartment, disconnect heater hoses. Remove 4
A/C-heater assembly nuts from engine compartment firewall. Inside
vehicle, remove A/C-heater assembly support brace screw, and swing
support brace out of way. Move passenger seat rearward.
3) Carefully pull A/C-heater assembly rearward until studs
and heater core tubes clear firewall. Lower A/C-heater assembly and
rotate assembly until studs are facing downward. Remove A/C-heater
assembly from vehicle. See Fig. 4.
4) Place A/C-heater assembly on work bench with assembly
housing cover facing down. Remove 2 screws securing A/C-heater
assembly housing cover to blower motor housing cover. Unplug vacuum
harness connector from panel/defrost door actuator.
5) Remove floor duct from A/C-heater assembly housing. Remove
2 screws securing A/C-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 A/C-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.
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procedure.
NOTE: On Durango rear A/C-heater assembly, blower motor and fan are
serviced as an assembly.
Removal (Durango - Rear)
1) Disconnect negative battery cable. Remove headliner from
passenger compartment of vehicle. Remove sun visors and sun visor arm
supports.
2) Remove coat hooks, overhead assist handle and dome light.
If equipped, remove overhead console. Remove air outlet bezel from
rear A/C-assembly. Remove rear blower motor switch. Remove upper
liftgate opening trim. Disengage "A", "B", "C", and "D" pillar trim as
necessary to prevent trim panel interference.
3) Move second and third row seats to cargo position. Move
front seats to full recline position. Remove headliner fasteners.
Carefully bow headliner and remove through lift gate opening.
4) Disconnect "B" pillar drain hoses from "Y" fittings.
Remove lower A/C-heater assembly cover. Disconnect blower motor
harness connector. Remove blower motor and fan assembly. To install,
reverse removal procedure.
Removal (Ram Pickup - Front)
1) Disconnect negative battery cable. Disconnect blower motor
cooling tube. Remove blower motor electrical connector from retainer.
Disconnect electrical connector. See Fig. 5.
2) Remove blower motor and fan assembly mounting screws.
Remove blower motor and fan assembly. Place reference marks on blower
motor and fan for reassembly 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.
BLOWER MOTOR RESISTOR
Removal & Installation (Dakota & Durango - Front)
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 screws. Remove blower
motor resistor. To install, reverse removal procedure.
Removal & Installation (Durango - Rear)
1) Rear blower motor resistor is located in A/C-heater
assembly. Disconnect negative battery cable. Remove headliner from
passenger compartment of vehicle. Remove sun visors and sun visor arm
supports.
2) Remove coat hooks, overhead assist handle and dome light.
If equipped, remove overhead console. Remove air outlet bezel from
rear A/C-assembly. Remove rear blower motor switch. Remove upper
liftgate opening trim. Disengage "A", "B", "C", and "D" pillar trim as
necessary to prevent trim panel interference.
3) Move second and third row seats to cargo position. Move
front seats to full recline position. Remove headliner fasteners.
Carefully bow headliner and remove through lift gate opening.
4) Disconnect "B" pillar drain hoses from "Y" fittings.
Remove lower A/C-heater assembly cover. Disconnect rear blower motor
resistor connector. Remove screw and rear blower motor resistor. To
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![DODGE RAM 1999 Service Owners Guide TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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TORQUE SPECIFICATIONS \
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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)\
A/C Compressor Mounting Bolts .............................. 20 (27)\
A/C Compressor Suction/Discharge Hose ...................... 17 (23)\
Service Valve-To-Compressor Fitting .................... ( 1) 35 (47)
INCH Lbs. (N.m)
Compressor Oil Filler Plug ................................ 84 (9.5)\
A/C-Heater Housing Mounting Nuts (Front) .................... 60 (7\
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A/C-Heater Housing Mounting Screws (Rear) ................. 106 (12\
)
( 1) - Wet torque fitting. Lubricate service valve coupling threads and
"O" rings with refrigerant oil.
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VACUUM DIAGRAMS
Fig. 9: Manual A/C-Heater System Vacuum Diagram (Dakota & Durango)
Courtesy of Chrysler Corp.
Page 128 of 1691
A/C S YSTE M G EN ER AL S ER VIC IN G
1999 D odge P ic ku p R 1500
1999 GENERAL SERVICING
A/C System General Servicing
All Models
USING R-134a REFRIGERANT
HANDLING/SAFETY PRECAUTIONS
1) Always work in a well-ventilated, clean area. Refrigerant
is colorless and invisible as a gas. Refrigerant is heavier than
oxygen and will displace oxygen in a confined area. Avoid breathing
refrigerant vapors. Exposure may irritate eyes, nose and throat.
2) Always wear eye protection when working around A/C system
and refrigerant. The system's high pressure can cause severe injury to
eyes and skin if a hose were to burst. If necessary, wear rubber
gloves or other protective clothing.
3) Refrigerant evaporates quickly when exposed to atmosphere,
freezing anything it contacts. If liquid refrigerant contacts eyes or
skin (frostbite), DO NOT rub eyes or skin. Immediately flush affected
area with cool water for 15 minutes and consult a doctor or hospital.
4) Never use R-134a in combination with compressed air for
leak testing. Pressurized R-134a in the presence of oxygen (air
concentrations greater than 60 percent by volume) may form a
combustible mixture. DO NOT introduce compressed air into R-134a
containers (full or empty), A/C system components, or service
equipment.
5) DO NOT expose A/C system components to high temperatures
(steam cleaning for example), as excessive heat will cause refrigerant\
system pressure to increase. Never expose refrigerant directly to open
flame. If refrigerant needs to be warmed, place bottom of refrigerant
tank in warm water. Water temperature MUST NOT exceed 125
F (52 C).
CAUTION: When R-134a is exposed to an open flame, drawn into engine,
or detected with a Halide (propane) leak tester, a poisonous
gas is formed. Keep work areas well ventilated.
6) Use care when handling refrigerant containers. DO NOT
drop, strike, puncture, or incinerate containers. Use DOT 4BW or DOT
4BA approved refrigerant containers.
7) Never overfill refrigerant containers. The safe filling
level of a refrigerant container MUST NOT exceed 60\% of the
container's gross weight rating. Store refrigerant containers at
temperatures less than 125
F (52 C).
8) R-134a refrigerant is sold and stored in 30- or 50-pound
Light Blue containers, while Freon (R-12) is stored in White colored
containers.
9) Refrigerant R-12 and R-134a must never be mixed, as they
and their desiccants and lubricants are not compatible. If the
refrigerants are mixed, system cross-contamination or A/C system
component failure may occur. Always use separate servicing and
refrigerant recovery/recycling equipment.
10) Read and follow equipment manufacturer's instructions for
all service equipment to be used. The Material Safety Data Sheet
(MSDS), provided by refrigerant manufacturer/supplier, contains
valuable information regarding the safe handling of refrigerants.
IDENTIFYING R-134a SYSTEMS & COMPONENTS
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To prevent refrigerant cross-contamination, use following
methods to identify R-134a based systems and components.
Fittings & "O" Rings
All R-134a based A/C systems use 1/2" - 16 ACME threaded
fittings (identifiable by square threads) and quick-connect service
ports. See Fig. 1.
Fig. 1: Identifying R-134a Service Ports
Courtesy of chrysler corp.
Underhood A/C Specification Labels
Most R-134a based systems will be identified through the use
Page 131 of 1691
Refrigerant R-12 based systems use mineral oil, while R-134a
systems use synthetic Polyalkylene Glycol (PAG) oils. Using a mineral
oil based lubricant with R-134a will result in A/C compressor failure
due to lack of proper lubrication.
Following are the most common R-134a refrigerant oils used by
most domestic vehicles:
Chrysler Corp., Eagle & Jeep
Use ND-8 PAG oil, SUN PAG 56 oil, SP-10 PAG Oil, or SP-20 PAG
oil.
Ford Motor Co.
Use YN-12B or YN-12C PAG Refrigerant Oil (specification WSH-
M1C231-B) or SP-20 PAG Oil (specification WST-M1C231-B2).
General Motors
On all models except Saturn, use PAG Refrigerant Oil (Part
No. 12345923). On Saturn, use Saturn PAG refrigerant oil.
NOTE: PAG oil absorbs moisture very rapidly, 2.3-5.6 percent by
weight as compared to a mineral oil absorption rate of .005
percent by weight.
NOTE: Use ONLY the specified oil for the appropriate system or A/C
compressor. Always check the underhood A/C specification
label or A/C compressor label before adding refrigerant oil
to A/C system.
SYSTEM SERVICE VALVES
SCHRADER-TYPE VALVES
NOTE: Although similar in construction and operation to a tire
valve, NEVER replace a Schrader-type valve with a tire
valve.
Schrader valve is similar in construction and operation to a
tire valve. See Fig. 4. When a test gauge hose is attached (hose has
built-in valve core depressor), Schrader stem is pushed inward to the
open position and allows system pressure to reach the gauge.
If test hose being used does not have a built-in core
depressor, an adapter must be used. Never attach hoses or adapters to
a Schrader valve unless it is first connected to manifold gauge set.
Fig. 4: Schrader Service Valve (Compressor Location Shown)
SPECIAL VALVE CONNECTORS
On some General Motors models, thread size on high-side
Page 132 of 1691
service valve (3/8" - 24 threads) is different from thread size on
low-side service valve (7/16" - 20 threads). Special adapters are
required to make this connection. See Fig. 5. These adapters are
available in 45-degree and 90-degree angles in addition to straight-
fixed and flexible adapters.
Fig. 5: Flexible High Side Adapter
R-134a SERVICE VALVES/PORTS
All vehicles with R-134a refrigerant use quick-disconnect
service valves/ports. All R-134a systems use quick-disconnect fittings
with sealing caps that thread into inside of service port instead of
onto outside of service port.
The high side uses a large service port, and the low side
uses a small service port. See Fig. 1. The R-134a service ports have
internal metric threads to help prevent the accidental connection of
R-12 servicing equipment.
There are 2 types of quick-disconnect service couplings which
can be used on R-134a systems. One type of service coupling depresses
service port valve when connection is made. The other type connects
onto service port but will not depress service port valve until a knob
is rotated. See Fig. 6.
Fig. 6: R-134a Service Couplings
Courtesy of chrysler corp.