brake DODGE RAM 1999 Service Repair Manual

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

"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

"E" ABBREVIATION TABLE

“E” ABBREVIATION TABLE
ABBREVIATION DEFINITION EAC Electric Assist Choke _ EACV Electric Air Control Valve _ EBCM Electronic Brake Control Module ECA Electronic Control Assembly ECAT Electronically Controlled Automatic
Transaxle ECM Electronic Control Module ECT Engine Coolant Temperature Sensor ECU Electronic Control Unit or Engine Control
Unit EDF Electric Drive Fan relay assembly EDIS Electronic Distributorless Ignition System EEC Electronic Engine Control EECS Evaporative Emission Control System EEPROM Electronically Erasable PROM EFE Early Fuel Evaporation _ EFI Electronic Fuel Injection _ EGO Exhaust Gas Oxygen sensor (see HEGO) EGR Exhaust Gas Recirculation system _ EGRC EGR Control solenoid or system _ EGRV EGR Vent solenoid or system _ EMR Emission Maintenance Reminder Module ESA Electronic Spark Advance _ ESC Electronic Spark Control _ EST Electronic Spark Timing _ ETR Emergency Tensioning Retractor _ EVAP Fuel Evaporative System _ EVIC Electronic Vehicle Information Center EVO Electronic Variable Orifice _ EVP EGR Valve Position Sensor _ EVR EGR Valve Regulator _ EVRV Electronic Vacuum Regulator Valve Elect. Electronic _ Eng. Engine _ Evap. Evaporative _ Exc. Except _

"F" ABBREVIATION TABLE

"F" ABBREVIATION TABLE
ABBREVIATION DEFINITION F Fahrenheit (Degrees) F/B Fuse Block FBC Feedback Carburetor FI Fuel Injector or Fuel Injection FICD Fast Idle Control Device FIPL Fuel Injector Pump Lever FP Fuel Pump FPM Fuel Pump Monitor FPR-VSV Fuel Pressure Regulator Vacuum Switching
Valve FWD Front Wheel Drive Fed. Federal Ft. Lbs. Foot Pounds

"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 _

BLOWER MOTOR VIBRATION
Possible causes of blower motor vibration include:
* Improper blower motor mounting.
* Improper blower wheel or fan mounting.
* Blower wheel or fan out of balance.
* Blower motor faulty.
BLOWER MOTOR NOISE
Possible causes of blower motor noise include:
* Foreign material in blower motor housing.
* Foreign material in A/C-heater housing.
* Improper blower motor mounting.
* Improper blower wheel or fan mounting.
* Blower motor faulty.
VACUUM CONTROL SYSTEM DIAGNOSIS
VACUUM CONTROL ONE-WAY CHECK VALVE
NOTE: Some models use brake booster check valve for vacuum source.
These models do not use another in-line vacuum check valve.
1) In engine compartment, locate Black vacuum hose that runs
from brake booster check valve or intake manifold, through firewall
near heater hoses or expansion valve. This supply vacuum hose goes to
A/C-heater control panel vacuum switch.
2) Within Black vacuum hose, disconnect and remove check
valve near intake manifold or brake booster. Connect vacuum gauge to
an external vacuum pump. Start vacuum pump. Plug end of hose probe on
vacuum gauge. Adjust bleed valve on vacuum gauge to obtain an exact
vacuum reading of 8 in. Hg.
3) Unplug and plug end of hose probe on vacuum gauge several
times to ensure exact vacuum reading. Connect vacuum gauge hose probe
to control panel side of check valve. Vacuum gauge reading should be 8
in. Hg. Replace check valve if vacuum leak exists.
4) Connect vacuum gauge hose probe to engine side of check
valve. Vacuum should flow through check valve. Replace check valve if
operation is not as described.
VACUUM CONTROLS
1) This test checks for proper function of control panel
vacuum circuits. Perform steps 1) through 4) under VACUUM CONTROL ONE-\
WAY CHECK VALVE.
2) Connect vacuum gauge hose probe to Black vacuum hose end
that leads to A/C-heater control panel switch. Position vacuum gauge
so gauge reading can be observed from inside vehicle.
3) Operate A/C-heater controls (sliding lever or push
buttons) in all mode positions (floor, defrost, panel, etc.). Pause
after each selection to allow vacuum actuators or motors to energize
and stabilize. Record vacuum gauge reading at each selection.
4) After each selection, vacuum reading should be 7.5-8 in.
Hg. Maximum vacuum reading drop is .75 in. Hg. If proper vacuum
reading cannot be obtained, vacuum leak exists in selected circuit.
5) To check for vacuum leak(s), disconnect 7-way A/C-heater
control panel vacuum harness connector. See Fig. 1. If necessary,
remove control panel from instrument panel to access A/C-heater
control panel vacuum harness connector, or remove lower instrument

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

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,

or the vehicle manufacturer's recommended service interval and must be
documented.
Some conditions indicate that service or part replacement is
required because the part in question is no longer providing the
function for which it is intended, does not meet a vehicle
manufacturer's design specification or is missing.
Example:
An exhaust pipe has corroded severely and has a hole in it
through which exhaust gases are leaking. Replacement of the
exhaust pipe in this case is required due to functional
failure.
Example:
A brake rotor has been worn to the point where it measures
less than the vehicle manufacturer's discard specifications.
Replacement of the rotor is required because it does not meet
design specifications.
Some conditions indicate that a service or part replacement
is suggested because the part is close to the end of its useful life
or addresses a customer's need, convenience or request. If a
customer's vehicle has one of these conditions, the procedure may be
only to suggest service.
Example:
An exhaust pipe is rusted, corroded or weak, but no leaks are
present. In this case, the exhaust pipe has not failed.
However, there is evidence that the pipe may need replacement
in the near future. Replacement of the pipe may be suggested
for the customer's convenience in avoiding a future problem.
Example:
The customer desires improved ride and/or handling, but the
vehicle's shocks or struts have not failed. In this case,
replacement may be suggested to satisfy the customer's
wishes. In this case, replacement of the shocks or struts may
not be sold as a requirement.
A customer, of course, has the choice of whether or not a
shop will service his or her vehicle. He or she may decide not to
follow some of your suggestions. When a repair is required, a MAP shop
must refuse partial service on that system if, in the judgment of the
service provider, proceeding with the work could create or continue an
unsafe condition. When a procedure states that required or suggested
repair or replacement is recommended, the customer must be informed of
the generally acceptable repair/replacement options whether or not
performed by the shop.
When presenting suggested repairs to the customer, you must
present the facts, allowing the customer to draw their own conclusions
and make an informed decision about how to proceed.
The following reasons may be used for required and suggested
services. These codes are shown in the "Code" column of the MAP
Uniform Inspection & Communications Standards that follow:
Reasons to Require Repair or Replacement
A - Part no longer performs intended purpose
B - Part does not meet a design specification (regardless of
performance)
C - Part is missing
NOTE: When a repair is required, the shop must refuse partial

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

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