ABS 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
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ABBREVIATIONS
1999 Dodge Pickup R1500
GENERAL INFORMATION
COMMONLY USED ABBREVIATION
"A" ABBREVIATION TABLE
"A" ABBREVIATION TABLE
ABBREVIATION DEFINITION A Amperes A/C Air Conditioning A/T Automatic Transmission/Transaxle AAP Auxiliary Accelerator Pump AB Air Bleed ABCV Air Bleed Control Valve ABDC After Bottom Dead Center ABRS Air Bag Restraint System ABS Anti-Lock Brake System AC Alternating Current ACC A/C Clutch Compressor ACCS A/C Cycling Switch ACCUM Accumulator ACCY Accessory ACT Air Charge Temperature Sensor ACV Thermactor Air Control Valve ADJ Adjust or Adjustable ADV Advance AFS Airflow Sensor AI Air Injection AIR or A.I.R. Air Injection Reactor AIS Air Injection System ALCL Assembly Line Communications Link ALDL Assembly Line Diagnostic Link ARC Automatic ASCD Automatic ASCS Air Suction Control Solenoid ASD Auto Shutdown ASDM Air Bag System Diagnostic Module ASV Air Suction Valve ATC Automatic Temperature Control ATDC After Top Dead Center ATF Automatic Transmission Fluid ATS Air Temperature Sensor AXOD Automatic Transaxle Overdrive Abs. Absolute Accy. Accessory Alt. Alternator or Altitude Amp. Ampere Assy. Assembly Auto. Automatic Aux. Auxiliary Avg. Average
3
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"B" ABBREVIATION TABLE
"B" ABBREVIATION TABLE
ABBREVIATION DEFINITION B/P Backpressure BAC By-Pass Air Control BAP Barometric Absolute Pressure Sensor BARO Barometric BBDC Before Bottom Dead Center BCM Body Control Module BDC Bottom Dead Center BHP Brake Horsepower BLK Black BLU Blue BMAP Barometric & Manifold Absolute Pressure
Sensor BOO Brake On-Off Switch BP Barometric Pressure sensor BPS Barometric Pressure sensor BPT Backpressure Transducer BRN Brown BTDC Before Top Dead Center BTU British Thermal Unit BVSV Bimetallic Switching Valve Baro. Barometric Batt. Battery Bbl. Barrel (Example:4-Bbl.) Blst. Ballast Blwr. Blower Brkr. Breaker
"C" ABBREVIATION TABLE
"C" ABBREVIATION TABLE
ABBREVIATION DEFINITION C Celsius (Degrees) C(3) Computer Controlled Coil Ignition C(4) Computer Controlled Catalytic Converter CANP Canister Purge solenoid CARB California Air Resources Board CAT Catalytic Converter CB Circuit Breaker CBD Closed Bowl Distributor CBVV Carburetor Bowl Vent valve cc Cubic Centimeter CCC Computer Command Control CCD Computer Controlled Dwell CCM Central Control Module CCO Converter Clutch Override CCOT Cycling Clutch Orifice Tube CCW Counterclockwise CDI Capacitor Discharge Ignition CEC Computerized Engine Control CFI Central Fuel Injection CID Cubic Inch Displacement CID Cylinder Identification sensor CIS Continuous Injection System CIS-E Continuous Injection System-Electronic
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"M" ABBREVIATION TABLE
"M" ABBREVIATION TABLE
ABBREVIATION DEFINITION mA Milliamps mV Millivolts mfd. Microfarads Mm Millimeters M/T Manual Transaxle or Transmission MA PFI Mass MA or MAF Mass Airflow MAF Mass Air Flow Sensor MAFS Mass Airflow System MAP Manifold Absolute Pressure Sensor MAT Manifold Air Temperature MCU Microprocessor Control Unit MCV Mixture Control Valve MEM-CAL Memory Calibration Chip MFI Multiport Fuel Injection MIL Malfunction Incicator Light MLP Manual Lever Position MPFI Multi Point Fuel Injection MPH Miles Per Hour MPI Multi-Point (Fuel ) Injection Man. Manual Mech. Mechanical Mem. Memory Mtr. Motor
"N" ABBREVIATION TABLE
"N" ABBREVIATION TABLE
ABBREVIATION DEFINITION N.m Newton-Meter NA Not Available NDS Neutral Drive Switch NGS Neutral gear Switch NOx Oxides of Nitrogen NPS Neutral Pressure Switch No. Number Nos. Numbers
"O" ABBREVIATION TABLE
"O" ABBREVIATION TABLE
ABBREVIATION DEFINITION O Oxygen O.D. Outside Diameter O/S Oversize O2 Oxygen OC Oxidation Catalyst OCC Output Circuit Check OD Overdrive ODO Odometer
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"R" ABBREVIATION TABLE
"R" ABBREVIATION TABLE
ABBREVIATION DEFINITION RABS Rear Anti-Lock Brake System RAC Remote Accessory Control RAM Random Access Memory RAP Retained Accessory Power RECIRC Recirculation RED Red RH Right hand ROM Read Only Memory RPM Revolutions Per Minute RVB Rear Vacuum Break RWAL Rear Wheel Anti-Lock Brake RWD Rear Wheel Drive Recirc. Recirculate or Recirculation Reg. Regulator Rly. Relay
"S" ABBREVIATION TABLE
"S" ABBREVIATION TABLE
ABBREVIATION DEFINITION SAW Spark Angle Word _ SBC Single Bed Converter _ SBEC Single Board Engine Controller _ SC Super Charged _ SCC Spark Control Computer _ SCS Air Suction Control Solenoid _ SDM Supplemental Restraint System Diagnostic Module _ SDU SRS Diagnostic Unit _ SEN Sensor _ SES Service Engine Soon _ SFI Sequential (Port) Fuel Injection _ SIG RTN Signal Return circuit _ SIL Shift Indicator Light _ SIR Supplemental Inflatable Restraint _ SMEC Single Module Engine Controller _ SOHC Single Overhead Cam _ SOL or SoL Solenoid _ SPFI Sequential Port Fuel Injection _ SPK Spark Control _ SPOUT Spark Output Signal _ SRS Supplemental Restraint System (Air Bag) _ SS 3/4-4/3 Shift Solenoid circuit _ SSI Solid State Ignition _ STAR Self-Test Automatic Readout _ STI Self Test Input circuit _ STO Self-Test Output _ SUB-O2 Sub Oxygen Sensor _ Sen. Or Sens. Sensor _ Sol. Solenoid _ Sprchg. Supercharger _ Strg. Steering _ Susp. Suspension _ Sw. Switch _ Sys. System _
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Use only NEW, moisture-free refrigerant oil in A/C systems.
Refrigerant oil is highly refined with a very low moisture content.
Oil container must be tightly closed when not in use, or moisture from
air will be absorbed into refrigerant oil.
Refrigerant R-134a systems use Polyalkylene Glycol (PAG)
refrigerant oil. Using a mineral oil based lubricant with R-134a
systems will result in A/C compressor failure due to lack of proper
lubrication.
All compressors have different lubrication requirements and
use different Polyalkylene Glycol (PAG) refrigerant oils. Use only the\
specified PAG refrigerant oil for the appropriate system and A/C
compressor. Always check the underhood A/C specification label or A/C
compressor label before adding refrigerant oil to A/C
compressor/system. See listing of refrigerant oils currently available
from the vehicle manufacturers.
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.
CHRYSLER CORP., JEEP & EAGLE
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.
SERVICING PRECAUTIONS
DISCHARGING SYSTEM
Discharge A/C system, using approved refrigerant
recovery/recycling equipment before loosening any fittings. Follow
refrigerant recovery/recycling equipment manufacturer's instructions.
DISCONNECTING LINES & FITTINGS
After system is discharged, carefully clean area around all
fittings to be opened. Always use 2 wrenches when loosening or
tightening fittings. Some refrigerant lines are connected with a
spring-lock coupling. Special tools may be required to disconnect
lines. To prevent dirt and moisture from entering system, cap all
openings as soon as lines are removed. DO NOT remove service valve
caps until ready to connect lines and fittings.
NOTE: All R-134a based systems use 1/2-16 ACME threaded fittings.
Ensure all replacement parts match the connections of the
system being worked on.
CONNECTING LINES & FITTINGS
Always use new a gasket or "O" rings when connecting lines or
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HEATER HOSES
HIGH PRESSURE RELIEF VALVES (HPRV)
IDLERS
IN-LINE FILTERS
METAL FITTINGS
METAL LINES
MIX AND AIR CONTROL DOORS (BLEND DOORS)
O-RINGS
ORIFICE TUBES
PILOT-OPERATED ABSOLUTES (POAS)
PLENUMS
PRESSURE CONTROL VALVES
PRESSURE SENSORS
PULLEYS
RADIATORS
RECEIVER-DRIERS
REFRIGERANT
REFRIGERANT OIL
RELAYS
SEALS
SERVICE PORTS
SPRING LOCK COUPLINGS
SUCTION THROTTLING VALVES (STVS)
SWITCHES (ELECTRICAL)
TENSIONERS
THERMISTORS AND PRESSURE SENSORS
THERMOSTATS AND HOUSINGS
VACUUM HOSES AND TUBES
VACUUM RESERVOIRS
VACUUM TUBES
VALVES IN RECEIVER (VIRS)
WATER PUMPS (ELECTRIC AUXILIARY)
WIRING HARNESSES AND CONNECTORS
MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
(1) a Pledge of Assurance to their Customers and (2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
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METAL FITTINGS
See
AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES .
METAL LINES
See
AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES .
MIX AND AIR CONTROL DOORS (BLEND DOORS)
See PLENUMS.
O-RINGS
O-RING INSPECTION \
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Condition Code Procedure
Leaking ................. A ........... ( 1) Require repair or
replacement.
( 1) - Require inspection of mating and sealing surface and
repair or replace as necessary.
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ORIFICE TUBES
ORIFICE TUBE INSPECTION \
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Bypassing internally .... A .. Require repair or replacement.
Filter screen torn ...... A ............ Require replacement.
Installation incorrect .. B ................. Require repair.
Restricted .............. A .. Require repair or replacement.
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PILOT-OPERATED ABSOLUTES (POAS)
PILOT-OPERATED ABSOLUTE (POA) INSPECTION \
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Condition Code Procedure
Connection damaged ...... B .. Require repair or replacement.
Fitting damaged ......... B .. Require repair or replacement.
Inoperative ............. A ........... ( 1) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Inoperative includes intermittent operation or out of
OEM specification.
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PLENUMS
PLENUM INSPECTION
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Condition Code Procedure
Air control door
binding ................ A ... Require repair or replacement
Air control door
broken ................. A .. Require repair or replacement.
Air control door
leaking ................ A .. Require repair or replacement.
Air control door
seized ................. 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.
Cracked ................. 2 .. Suggest repair or replacement.
Drain hole restricted ... A ................. Require repair.
Drain plugged ........... A ................. Require repair.
Duct disconnected ....... A .. Require repair or replacement.
Duct leaking ............ A .. Require repair or replacement.
Duct missing ............ C ............ Require replacement.
Duct restricted ......... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Noisy ................... 2 ..... Suggest cleaning or repair.
Odor .................... 2 ..... Suggest cleaning or repair.
Restricted .............. A .... Require cleaning, repair, or
replacement.
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PRESSURE CONTROL VALVES
See:
* EVAPORATOR PRESSURE REGULATORS (EPRS)
* HIGH PRESSURE RELIEF VALVES (HPRV)
* PILOT-OPERATED ABSOLUTES (POAS)
* SUCTION THROTTLING VALVES (STVS)
* VALVES IN RECEIVER (VIRS)
PRESSURE SENSORS
See THERMISTORS AND PRESSURE SENSORS .
PULLEYS
PULLEY INSPECTION \
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Condition Code Procedure
Alignment incorrect ..... B .. Require repair or replacement.
Application incorrect ... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
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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
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evaporator inlet line and "O" rings with refrigerant oil. Lubricate
orifice tube and "O" ring with refrigerant oil. Insert orifice tube
into evaporator inlet line with short screen toward condenser.
2) Tighten liquid line nut to 18 ft. lbs. (24 N.m). To
complete installation, reverse removal procedure. Evacuate, charge,
and test system for proper operation.
Removal ("F" Body)
Discharge A/C system, using approved recovery/recycling
equipment. Disconnect negative battery cable. Disconnect A/C pressure
switch connector. Use a backup wrench to hold evaporator fitting, and
loosen evaporator liquid line fitting. Remove bolt. Disconnect
evaporator liquid line. Remove and discard "O" rings. Using needle-
nose pliers, remove orifice tube from evaporator inlet line.
Installation
1) Clean evaporator line fitting with refrigerant oil. Coat
inside of inlet line and evaporator line "O" rings with refrigerant
oil. Lubricate orifice tube and "O" ring with refrigerant oil and
insert them into inlet line. Insert orifice tube into evaporator inlet
line with long screen inlet end toward condenser.
2) Tighten bolt to 12 ft. lbs. (16 N.m). Tighten evaporator
line fitting to 28 ft. lbs. (38 N.m). To complete installation,
reverse removal procedure. Evacuate, charge, and test system for
proper operation.
Removal ("J" & "N" Body)
1) Locate orifice tube. See ORIFICE TUBE LOCATION &
REMOVER/INSTALLER APPLICATION table. Discharge A/C system, using
approved recovery/recycling equipment. On "J" body, remove upper
closeout panel. On "N" body, raise and support vehicle. On all models,
disconnect condenser-to-evaporator line at condenser outlet and
discard "O" rings.
2) Disconnect condenser-to-evaporator line clip on right side
body rail, behind engine mount. Remove orifice tube using Orifice Tube
Remover/Installer (J-26549-E) or needle-nose pliers.
3) If difficulty is encountered during removal of a plugged
or restricted orifice tube, remove as much residue as possible. Using
a heat gun, carefully apply heat 1/4" from dimples on condenser inlet
line. Be careful not to overheat line.
4) If A/C pressure switch is located near orifice tube,
remove switch to protect it from heat. While heat is being applied,
grip orifice tube using orifice tube remover/installer or needle-nose
pliers. Use a turning motion along with a push-pull motion to loosen
and remove orifice tube.
Installation
1) Coat inside of condenser inlet line and "O" rings with
refrigerant oil. Lubricate orifice tube "O" ring with refrigerant oil
and insert into condenser inlet line. Insert orifice tube into
condenser inlet line with shorter screen toward evaporator.
2) Connect condenser-to-evaporator line clip on right side
body rail. Lubricate "O" rings and connect condenser inlet line.
Tighten condenser inlet line nut to 12 ft. lbs. (16 N.m). Install
closeout panel. Evacuate, charge, and test system for proper
operation.
Removal ("W" Body)
1) Locate orifice tube. See ORIFICE TUBE LOCATION &
REMOVER/INSTALLER APPLICATION table. Remove air cleaner and duct
assembly. Discharge A/C system, using approved recovery/recycling
equipment. Disconnect negative battery cable. Disconnect ABS modulator
and A/C pressure sensor/fan switch electrical connectors.