heater DODGE RAM 1999 Service Manual PDF
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 762 of 1691
Outer ring slipped out of
position ............... A ........... Require replacement.
Positioned incorrectly .. A . Require repair or replacement.
Rubber damping material
deteriorated ........... 1 ........... Suggest replacement.
Seal surface worn, causing
a leak ................. A . Require repair or replacement.
Threads damaged ......... A . Require repair or replacement.
Threads stripped (threads
missing) ............... A ........... Require replacement.
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HEATER CONTROL VALVES
HEATER CONTROL VALVE 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.
Bypassed ................ A ............ Require replacement.
Coolant leak ............ A .. Require repair or replacement.
Malfunctioning .......... A ........... ( 1) Require repair or
replacement.
Missing ................. C ............ Require replacement.
Restricted .............. A .. Require repair or replacement.
Vacuum leak ............. A .. Require repair or replacement.
( 1) - Includes inoperative, intermittent operation, or
failure to perform all functions.
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HEATER CORES
HEATER CORE INSPECTION \
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Condition Code Procedure
Air flow restriction .... A .. Require repair or replacement.
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.
Bypassed ................ A .. Require repair or replacement.
Connection leaking ...... A .. Require repair or replacement.
Corroded ................ 1 .. Suggest repair or replacement.
Fins damaged, affecting
performance ............ A .. Require repair or replacement.
Fins damaged, not
affecting performance .. 2 .. Suggest repair or replacement.
Internal restrictions,
Page 763 of 1691
affecting performance .. A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
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HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS
NOTE: When replacing fuel lines and hoses, replace with product
that meets or exceeds OEM design specifications.
HOSE AND TUBE COUPLER, CONNECTOR AND CLAMP INSPECTION
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Connected incorrectly ... A ................. Require repair.
Corroded, not reusable .. 1 ............ Suggest replacement.
Cracked ................. A ............ Require replacement.
Insufficient clamping
force, allowing hose to
leak ................... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Safety clip missing (not
leaking) ............... C ... Require replacement of safety
clip.
Stripped ................ A ............ Require replacement.
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HOSE CLAMPS
See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .
HOSE CONNECTORS
See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .
HOSE COUPLERS
See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .
HOSES AND TUBES (FUEL LINES, RADIATOR, VACUUM, BY PASS,
HEATER, RECOVERY TANK AND OIL COOLERS)
HOSE AND TUBE (FUEL LINE, RADIATOR, VACUUM, BY PASS, HEATER,
RECOVERY TANK AND OIL COOLER) INSPECTION
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Connected incorrectly ... A ................. Require repair.
Corroded, not reusable .. 1 ............ Suggest replacement.
Cracked ................. A ............ Require replacement.
Dry-rotted .............. 1 .. Suggest repair or replacement.
Hard .................... 1 .. Suggest repair or replacement.
Inner fabric (webbing)
damaged ................ A ............ Require replacement.
Insufficient clamping
force, allowing hose to
leak ................... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Maintenance intervals ... 3 ............ Suggest replacement.
Page 801 of 1691
![DODGE RAM 1999 Service Manual PDF check for accepted cleaning procedure. \
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TUB](/img/12/56915/w960_56915-800.png "DODGE RAM 1999 Service Manual PDF check for accepted cleaning procedure. \
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TUB")
check for accepted cleaning procedure. \
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TUBE CLAMPS
See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .
TUBE CONNECTORS
See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .
TUBE COUPLERS
See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .
TUBES
See HOSES AND TUBES (FUEL LINES , RADIATOR, BY PASS, HEATER,
RECOVERY TANK AND OIL COOLERS).
TURBO CHARGERS
TURBO CHARGER 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.
Boost pressure
incorrect .............. A ........... ( 1) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Oil seal (internal)
leaking ................ A .. Require repair or replacement.
Vibrates ................ A .. Require repair or replacement.
( 1) - Boost pressure problems may be caused by other systems
or components.
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VACUUM CONNECTIONS
See VACUUM HOSES, TUBES AND CONNECTIONS (NON-METALLIC) .
VACUUM HOSES, TUBES AND CONNECTIONS (NON-METALLIC)
VACUUM HOSE, TUBE AND CONNECTION (NON-METALLIC) INSPECTION \
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Condition Code Procedure
Leaking ................. A .. Require repair or replacement.
Melted .................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Oil-soaked (spongy) ..... 1 ............ Suggest replacement.
Page 820 of 1691
GEN ER AL C O OLIN G S YSTE M S ER VIC IN G
1999 D odge P ic ku p R 1500
GENERAL INFORMATION
General Cooling System Servicing
* PLEASE READ THIS FIRST *
The following article is for general information only.
Information may not apply to all years, makes and models. See specific
article in the ENGINE COOLING section.
DESCRIPTION
The basic liquid cooling system consists of a radiator, water
pump, thermostat, electric or belt-driven cooling fan, pressure cap,
heater, and various connecting hoses and cooling passages in the block
and cylinder head.
MAINTENANCE
DRAINING
Remove radiator cap and open heater control valve to maximum
heat position. Open drain cocks or remove plugs in bottom of radiator
and engine block. In-line engines usually have one plug or drain cock,
while "V" type engines will have 2, one in each bank of cylinders.
CLEANING
A good cleaning compound removes most rust and scale. Follow
manufacturer's instructions in the use of cleaner. If considerable
rust and scale has to be removed, cooling system should be flushed.
Clean radiator air passages with compressed air.
FLUSHING
CAUTION: Some manufacturers use an aluminum and plastic radiator.
Flushing solution must be compatible with aluminum.
Back Flushing
Back flushing is an effective means of removing cooling
system rust and scale. The radiator, engine and heater core should be
flushed separately.
Radiator
To flush radiator, connect flushing gun to water outlet of
radiator and disconnect water inlet hose. To prevent flooding engine,
use a hose connected to radiator inlet. Use air in short bursts to
prevent damage to radiator. Continue flushing until water runs clear.
Engine
To flush engine, remove thermostat and replace housing.
Connect flushing gun to water outlet of engine. Flush using short air
bursts until water runs clean.
Heater Core
Flush heater core as described for radiator. Ensure heater
control valve is set to maximum heat position before flushing heater.
Page 823 of 1691
HEA TE R S YSTE M
1999 D odge P ic ku p R 1500
1999 HEATER SYSTEMS
RWD Trucks & Vans
CHRYSLER
Dakota, Durango, Ram Pickup, Ram Van/Wagon
DESCRIPTION
All models use a blend-air system. Outside air enters heater
through cowl opening and passes through a plenum chamber to heater
core. Blend air door in heater housing controls temperature by either
directing air through or around heater core. Air flow is then directed
through dash panel to air distribution duct in passenger compartment.
On Durango, air taken from the front heater system is fed
back through an air duct into the center console. At the rear of the
center console, passengers can operate a 3 mode switch to adjust air
flow. Temperature and blower speeds are controlled by the front heater
control panel.
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.
OPERATION
HEATER CONTROL PANEL
Blower Motor Switch
Fan speed is controlled with a rotary blower motor switch.
There are 4 different fan speed settings: one low speed, 2 medium
speeds, and one high speed.
Mode Control Knob
A rotary mode switch is used to control air flow. There are 5
different modes of operation: panel, floor/panel, floor,
floor/defrost, and defrost.
Temperature Control Knob
Rotary control knob determines discharge air temperature by
positioning blend/air door. On Dakota and Durango, temperature blend-
air door is cable operated. On Ram Pickup and Ram Van/Wagon,
temperature blend-air door is electrically operated. When a hot
temperature is selected, all air flows through heater core.
ADJUSTMENTS
TEMPERATURE CONTROL CABLE ADJUSTMENT
Dakota & Durango
1) Ensure temperature control cable housing and core are
connected at both heater control panel and heater assembly. Ensure
heater control panel is properly installed.
2) Rotate temperature control knob so that knob pointer is at
12 o'clock position. Pull temperature control knob straight out from
heater control panel until perimeter of knob (not knob pointer)
protrudes about .25" (6 mm) from face of heater control panel.
3) Rotate temperature control knob clockwise so that knob
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 825 of 1691
Fig. 1: Identifying Blower Motor Relay Terminals
Courtesy of Chrysler Corp.
BLOWER MOTOR RESISTOR
1) Disconnect negative battery cable. Disconnect blower motor
resistor harness connector. Using an ohmmeter, check for continuity
between all blower motor resistor terminals. If continuity exists
between all terminals, go to next step. If continuity does not exist
between all terminals, replace faulty blower motor resistor.
2) Check for open or short in circuits between blower motor
resistor and heater control panel. Also check for open or short in
wire between blower motor resistor and blower motor.
BLOWER MOTOR SWITCH
Dakota, Durango & Ram Pickup
1) Using a voltmeter, check for battery voltage at underhood
power distribution center fuse No. 5 (40-amp) on Dakota and Durango;
fuse No. 12 (40-amp) on Ram Pickup. If battery voltage exists, go to
next step. If battery voltage does not exist, check for open in Red
wire between battery and underhood power distribution center. If Red
wire is okay, replace underhood power distribution center.
2) Disconnect negative battery cable. Remove heater control
panel. See HEATER CONTROL PANEL R & I . Disconnect heater control panel
harness connector. Using an ohmmeter, check for continuity between
heater control panel harness connector terminal No. 7 (Black wire on
Dakota and Durango; Black/Orange on Ram Pickup) and ground. If
continuity exists, go to step 4).
3) If continuity does not exist, repair open in Black wire or
Black/Orange wire between heater control panel harness connector
terminal No. 7 and ground connector located at lower right corner of
instrument panel (Dakota and Durango) or behind center of instrument
panel (Ram Pickup).
4) Place heater mode control knob to any position except OFF.
Page 826 of 1691
Using an ohmmeter, check for continuity between heater control panel
connector terminal No. 7 and terminals No. 3, 4, 5 and 6 while
rotating blower motor switch. See Fig. 2.
5) If continuity does not exist at any terminal, replace
faulty heater control panel. If continuity exists as specified, check
for open in circuits between heater control panel and blower motor
resistor. Also check for an open in circuit between heater control
panel and blower motor.
Fig. 2: Identifying Blower Motor Switch Connector Terminals (Dakota,
Durango & Ram Pickup)
Courtesy of Chrysler Corp.
Ram Van/Wagon
1) Disconnect negative battery cable. Remove heater control
panel. See HEATER CONTROL PANEL R & I . Disconnect heater control panel
harness connector. Using an ohmmeter, check for continuity between
heater control panel C3 harness connector terminal "C" (Black wire)
and ground. See Fig. 4. Go to next step.
2) If continuity exists, go to next step. If continuity does
not exist, repair open in Black wire between heater control panel and
ground connector located at lower right of steering column.
3) Place heater mode control knob to any position except OFF.
Using an ohmmeter, check for continuity between heater control panel
C3 connector terminals "B" (Violet wire) and "C" (Black wire). If
continuity exists, go to next step. If continuity does not exist,
replace faulty heater control panel.
4) Using an ohmmeter, check for continuity between heater
control panel C3 connector terminal "B" (Violet wire) and C1 connector\
terminal "E" (Violet wire). See Fig. 3. If continuity exists, go to
next step. If continuity does not exist, repair open in Violet wire
between heater control panel C3 and C1 connectors.
5) Using an ohmmeter, check for continuity between heater
control panel C1 connector terminal "E" and terminals "B", "C" and "D"
while rotating blower motor switch. See Fig. 3.
6) If continuity does not exist at any terminal, replace
faulty heater control panel. If continuity exists as specified, check
Page 827 of 1691
for open in circuits between heater control panel and blower motor
resistor. Also check for an open in circuit between heater control
panel connector and blower motor relay.
Fig. 3: Identifying Heater Control Panel C1 Connector Terminals
Courtesy of Chrysler Corp.
Fig. 4: Identifying Heater Control Panel C3 Connector Terminals
Courtesy of Chrysler Corp.
HEATER CONTROL PANEL
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\
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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