1999 DODGE RAM battery replacement

CLUTCH ASSEMBLY
Removal (Except Grand Cherokee)
Remove compressor shaft bolt. Remove clutch plate and shims.
Tighten a 10-mm bolt into clutch hub bolt hole to remove clutch hub
and shims. Remove snap ring, and remove rotor and pulley assembly.
Remove snap ring, and disconnect clutch coil lead. Remove clutch coil.
Installation
1) Install clutch coil so pin in back of coil aligns with
hole in front compressor housing. Connect clutch coil lead. Install
snap ring with bevel side facing outward. Ensure snap ring is properly
seated in groove. Install rotor and pulley assembly. Install shims and
snap ring. Install clutch hub.
2) Install dial indicator at front of clutch hub to measure
clutch hub air gap. Using battery voltage, energize clutch coil.
Proper air gap is 0.014-0.026" (0.35-0.65 mm). Add or remove shims to
obtain correct air gap. Install compressor shaft bolt. On Concord and
Intrepid, tighten compressor shaft bolt to 11-15 ft. lbs. (15-20 N.m).\
On all other models, tighten compressor shaft bolt to 10 ft. lbs. (14
N.m).
NOTE: On Grand Cherokee, compressor clutch can be serviced in
vehicle without discharging A/C system.
Removal (Grand Cherokee)
Disconnect and isolate negative battery cable. Remove
serpentine drive belt. Remove compressor shaft bolt. Using a plastic
mallet, tap clutch plate to loosen from compressor shaft. Remove
clutch plate, shaft key and shims. See Fig. 5. Remove snap ring, and
remove pulley assembly. Remove snap ring, and disconnect clutch coil
lead. Remove clutch coil.
Installation
1) Install clutch coil so pin in back of coil aligns with
hole in front compressor housing. Connect clutch coil lead. Install
snap ring with bevel side facing outward. Ensure snap ring is properly
seated in groove. Align snap ring eyelets to the left or right of
clutch coil pin. Install rotor and pulley assembly. Install shims and
snap ring. Install clutch hub.
2) Hold clutch plate tight against shims and measure air gap
between clutch plate and pulley face. Air gap should be 0.014-0.026"
(0.35-0.65 mm). Add or remove shims as necessary. Install compressor
shaft bolt. Tighten compressor shaft bolt to 115 INCH lbs. (13 N.m).
To complete installation, reverse removal procedure.
3) After completing compressor clutch installation, start
engine. Set A/C-heater control to recirculated air mode and high
blower motor speed. Set engine speed to 1500-2000 RPM. Cycle
compressor on for 5 seconds and off for 5 seconds, about 20 times to
break-in clutch.
SHAFT SEAL
NOTE: Shaft seal replacement procedure is for 10PA17C compressor.
Shaft seal replacement procedure for 10PA17 compressor is not
available.
Removal
1) Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Remove A/C compressor. Drain oil from
compressor, and measure amount drained. Remove clutch hub, shims,
rotor and pulley assembly, and clutch coil. See CLUTCH ASSEMBLY. See

ORIFICE TUBE REPLACEMENT
CHRYSLER CORP.
Removal & Installation (Dakota)
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
liquid line at condenser outlet tube. Cover open refrigerant fittings
to protect from moisture and dirt.
2) Using 2 wrenches, loosen tube fitting and separate front
half of liquid line from rear half of liquid line. Using needle nose
pliers, remove fixed orifice tube from rear half of liquid line. Note
fixed orifice tube orientation for correct installation.
3) To install, reverse removal procedure. Ensure fixed
orifice tube is positioned correctly. Evacuate, charge, and leak test
A/C system. Ensure A/C system operates properly.
NOTE: On Ram Pickup, if the fixed orifice tube is faulty or
plugged, the liquid line and orifice tube must be replaced as
an assembly.
Removal & Installation (Ram Pickup)
Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Disconnect
liquid line from evaporator inlet and condenser outlet tubes. Cover
open refrigerant fittings to protect from moisture and dirt.
Disconnect liquid line retaining clips. Remove liquid line and orifice
tube. To install, reverse removal procedure. Evacuate, charge, and
leak test A/C system. Ensure A/C system operates properly.
FORD MOTOR CO.
NOTE: Replace orifice tube whenever compressor is replaced. Fixed
orifice tube is located in the condenser-to-evaporator liquid
line.
NOTE: DO NOT use pliers to remove fixed orifice tube or twist
orifice tube in liquid line. Doing so will cause plastic
orifice tube body to break inside condenser-to-evaporator
liquid line.
Fixed Orifice Tube Replacement (Except Continental, Mustang &
Villager)
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. On Contour
and Mystique, move power steering fluid reservoir to one side without
disconnecting hoses.
2) On all models, disconnect condenser-to-evaporator
discharge (liquid) line. Remove and discard "O" rings from line. Pour
a small amount of refrigerant oil into inlet to lubricate orifice "O"
rings.
3) Insert orifice tube remover/installer into tube and turn
tool to right to engage tangs on orifice tube. See Fig. 18. Hold "T"
handle of tool and slowly tighten nut down onto discharge line to
slowly pull orifice tube out. If orifice tube breaks off when removal
is attempted, use orifice tube extractor to pull the broken section
out. See Fig. 19.
4) Ensure replacement orifice tube is fitted with "O" ring(s)\
lubricated with clean refrigerant oil. Insert tube with short end
toward evaporator, until seated. Reconnect high pressure line. On
Contour and Mystique, tighten connection to 18 ft. lbs. (24 N.m).

foot wires to terminals of a 12-volt battery. After air bag module
deploys, let module cool off and allow dust to settle before
approaching.
POST-COLLISION INSPECTION
When a vehicle has been involved in a collision, certain
components of the passive restraint system must be inspected or
replaced. See PASSIVE RESTRAINT SYSTEM INSPECTION article in the
GENERAL INFORMATION section for post-collision inspection information.
REMOVAL & INSTALLATION
* PLEASE READ THIS FIRST *
WARNING: Failure to follow air bag service precautions may
result in air bag deployment and personal injury. See
SERVICE PRECAUTIONS . After component replacement,
ensure proper system operation. See SYSTEM OPERATION CHECK.
CAUTION: When battery is disconnected, vehicle computer and memory
systems may lose memory data. Driveability problems may
exist until computer systems have completed a relearn cycle.
See COMPUTER RELEARN PROCEDURES in GENERAL INFORMATION
before disconnecting battery.
AIR BAG CONTROL MODULE (ACM)
WARNING: ACM contains impact sensor, which enables SRS to activate air
bag. To avoid accidental air bag deployment, DO NOT connect
ACM electrically to system unless it is bolted to vehicle.
Removal
1) Before proceeding, see SERVICE PRECAUTIONS. Disable air
bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove bottom
of center console (ACM trim cover).
2) On M/T models, remove center console from floor panel
transmission tunnel. On A/T models, remove screws securing trim cover
to ACM mounting bracket. See Fig. 2. Pull top of trim cover rearward
to release snap clips from instrument panel support bracket.
3) On all models, loosen but do not remove screws on sides
that secure instrument panel support bracket to ACM mounting bracket.
See Fig. 3 .
4) Remove nuts securing support bracket to studs on lower
instrument panel. Disconnect wire harness retainer from hole in
support bracket. Pull top of support bracket away from instrument
panel studs and fold down over ACM until it is laying on floor panel.
Unplug wire harness connector from ACM.
CAUTION: Always replace ACM and ACM mounting bracket as an assembly.
Replacement ACM includes a NEW mounting bracket. DO NOT mount
NEW ACM to old mounting bracket.
5) Remove screws securing mounting bracket to floor panel
transmission tunnel. Remove ACM, mounting bracket and support bracket
as a unit from floor panel.
Installation
To complete installation, reverse removal procedure. Install
ACM with arrow pointing toward front of vehicle. Connect ACM
connectors, ensuring connectors are locked into position. Tighten ACM

TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)
Steering Wheel Nut ............................... 45 (61)
INCH Lbs. (N.m)
ACM Mounting Screws &
Support Bracket Nuts ........................ 125 (14.0)
Driver-Side Air Bag Module Screws .......... 80-100 (9-11)
Front Impact Sensor Screws ............... 40-50 (4.5-5.6)
PAD Switch Mounting Screws ...................... 20 (2.2)
Passenger-Side Air Bag Module Screws ............ 80 (9.0)









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DIAGNOSIS & TESTING
* PLEASE READ THIS FIRST *
WARNING: Always follow air bag service precautions to avoid air bag
deployment and possible personal injury. Refer to procedure
under SERVICE PRECAUTIONS . After component replacement,
ensure proper system operation. See SYSTEM OPERATION CHECK.
CAUTION: When battery is disconnected, vehicle computer and memory
systems may lose memory data. Driveability problems may
exist until computer systems have completed a relearn cycle.
See COMPUTER RELEARN PROCEDURES in GENERAL INFORMATION.
NOTE: Although other scan tools are available, manufacturer
recommends using Diagnostic Readout Box (DRB) tester to
access SRS on-board diagnostics. Following diagnosis and
testing procedures are designed for use with DRB.
SELF-DIAGNOSTIC SYSTEM
SRS is monitored by Air Bag Control Module (ACM). ACM
contains safing sensor, an integral sensor in circuitry of system,
which is used to deploy air bag modules.
ACM monitors critical input and output circuits within air
bag system, ensuring they operate correctly. Some circuits are tested
continuously; others are checked under certain conditions. ACM
provides information about air bag system, through AIR BAG warning
light and DRB tester. Each circuit monitored by ACM has a
corresponding fault code or fault message assigned to it.
Active Codes
A code becomes active as soon as a malfunction is detected.
An active trouble code indicates an on-going malfunction. This means
the defect is currently there every time the ACM checks that
circuit/function. An active trouble code can not be erases. Active
codes will automatically erase when the reason for the code has been
corrected.
With the exception of warning light trouble codes or
malfunctions, when a malfunction is detected, AIR BAG warning light
remains illuminated for a minimum of 12 seconds or as long as the
malfunction is present.
Stored Codes
Trouble codes are automatically stored in ACM memory as soon

as the malfunction is detected. A stored code indicates there was an
active code present at some time. However, the code currently may not
be present as an active code, although another active code could be.
When a trouble code occurs, the AIR BAG warning light
illuminates for 12 seconds minimum (even if problem existed for less
than 12 seconds). Code is stored, along with time in minutes it was
active, and number of times ignition has been cycled since problem was
detected.
When and if malfunction ceases to exist, an ignition cycle
count will be initiated for that code. If ignition cycle count reaches
100 without a reoccurrence of the same malfunction, DTC is erased and
that ignition cycle counter is reset to zero. If malfunction reoccurs
before count reaches 100, ignition cycle counter will be reset and DTC
will continue to be a stored code.
If a particular code is not active while performing
diagnostic test for that code, code diagnostic test may not locate the
source of the problem. In this case, stored code can only indicate an
area of system to inspect.
If no obvious problems are found, erase stored codes, and
with ignition on, wiggle wiring harness and connectors. Recheck for
codes periodically as you work through system. This procedure may
uncover a difficult problem to locate.
PRETEST INSPECTION & DIAGNOSTIC PROCEDURE
Following precautions and procedures must be followed:
* Always follow air bag service precautions to avoid air bag
deployment and possible personal injury. Refer to procedure
under See SERVICE PRECAUTIONS.
* After component replacement, ensure proper system operation.
See SYSTEM OPERATION CHECK .
* When testing voltage or continuity at ACM, use terminal side
(not wire end) of connector. DO NOT probe wire through
insulation.
* Always check if any TECH SERVICE BULLETINS (TSBs) apply to
vehicle.
* When using diagnostic charts, DO NOT skip any steps in chart
or incorrect diagnosis may result. Always perform
SYSTEM OPERATION CHECK after repairs are made.
* Always use most current DRB diagnostic program cartridge
available to prevent erroneous codes or test results.
* When using diagnostic charts, use DRB voltmeter unless
instructed to use an external voltmeter. Never use a test
light in place of a voltmeter.
* When performing electrical tests, prevent accidental
shorting of terminals. Such shorts can damage fuses or
components and may cause a second code (message) to be
set, making diagnosis of original problem more difficult.
* Vehicle must have a fully-charged battery and functional
charging system.
* Each time a connector is disconnected, inspect it to ensure
it is in good condition. Always focus on circuit being
tested. Dirt, water and corrosion, are most common problems
in connectors.
* Always disconnect DRB after use.
* Always disconnect DRB before charging battery.
USING DRB
1) Refer to DRB user guide for instructions and assistance
with reading trouble codes and other DRB functions. Under normal
operation DRB will display one of only 2 error messages: User-

For Vehicle Theft Security System (VTSS) testing procedures,
see appropriate BODY CONTROL COMPUTER TESTS article.
REMOVAL & INSTALLATION
CENTRAL TIMER MODULE (CTM)
NOTE: Before removing Central Timer Module (CTM), use scan tool to
view settings for programmable features. Use these settings
to program replacement CTM.
Removal & Installation (Ram Pickup)
1) Disconnect negative battery cable. Remove left underdash
cover and knee bolster reinforcement. Remove 2 CTM retaining screws at
right side of underdash opening. See Fig. 2.
2) Slide CTM down into opening far enough to gain access to
connectors. Disconnect harness connectors and remove CTM from
underdash. To install, reverse removal procedure. Reprogram new CTM.
See appropriate BODY CONTROL COMPUTER TESTS article.
Removal & Installation (Ram Van & Ram Wagon)
1) Disconnect negative battery cable. Remove left underdash
cover and knee bolster reinforcement. Remove 3 CTM retaining screws
from left center instrument panel support. See Fig. 3.
2) Slide CTM away from mounting enough to gain access to
connectors. Disconnect harness connectors and remove CTM from
underdash. To install, reverse removal procedure. Reprogram new CTM.
See appropriate BODY CONTROL COMPUTER TESTS article.
Fig. 2: Identifying CTM Location (Ram Pickup)
Courtesy of Chrysler Corp.

Minimum Compression Pressure
Dakota
2.5L ........................................................ (1)
3.9L, 5.2L & 5.9L ............................. 100 psi (690 kPa)\
Durango ........................................ 100 psi (690 kPa)\
Ram Pickup ..................................... 100 psi (690 kPa)\
Ram Van Ram Wagon .............................. 100 psi (690 kPa)\
Maximum Variation Between Cylinders ............................ ( 1)
( 1) - Information is not available from manufacturer.









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FUEL SYSTEM
FUEL PRESSURE RELEASE
WARNING: Fuel system is under high pressure. ALWAYS release fuel
pressure before attempting to open system for testing or
component replacement. DO NOT allow fuel to flow onto engine
or electrical parts while testing fuel system components.
Vehicles With Fuel Rail Test Port
1) Loosen fuel tank filler cap. Ensure ignition is off.
Remove protective cap from fuel rail test port.
2) Place one end of Fuel Pressure Release Hose (C-4799-1)
into an approved fuel container. Attach remaining end of hose to fuel
rail test port. Use care, as fuel system may be under pressure. Fuel
pressure will be released from fuel system. Remove hose, reinstall
protective cap, and fuel tank filler cap.
3) Wait 5 seconds. Use care when disconnecting fuel lines, as
some fuel pressure may still exist in fuel lines.
NOTE: One or more DTCs may set when fuel pump relay is removed.
Clear DTCs from PCM after fuel pressure release procedure. To
clear DTCs from PCM, see CLEARING DTCS under SELF-DIAGNOSTIC
SYSTEM in SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS
article.
Vehicles Without Fuel Rail Test Port
1) Remove gas cap. Using a non-metallic tool, open flapper
valve in filler neck to relieve pressure. Remove fuel pump relay from
Power Distribution Center (PDC). Relays are identified on label under
PDC cover. Start and run engine until it stalls. Attempt to start
engine. Continue restarting engine until it will no longer run. Turn
ignition off.
CAUTION: DO NOT supply power to fuel injector for more than 4 seconds,
or fuel injector may be damaged.
2) Disconnect any fuel injector connector. Connect a jumper
wire between either fuel injector terminal and positive battery
terminal. Connect another jumper wire to other fuel injector terminal.
Momentarily touch other end of jumper wire to negative battery
terminal.
3) Place a shop towel under fuel line quick-connector at fuel
rail. Use care when disconnecting fuel lines, as some fuel pressure
may still exist in fuel lines. Disconnect fuel line quick-connector.
Reinstall fuel pump relay in PDC. Clear DTCs from PCM. To clear DTCs
from PCM, see CLEARING DTCS under SELF-DIAGNOSTIC SYSTEM in SELF-
DIAGNOSTICS - JEEP, TRUCKS & RWD VANS article.
FUEL PRESSURE TEST

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AMPLIFIERS
See
RECEIVERS, AMPLIFIERS, EQUALIZERS AND SUB-WOOFER VOLUME CONTROLS .
ANTENNAS
ANTENNA 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.
Broken .................. A ............ Require replacement.
Bent .................... 2 .. Suggest repair or replacement.
Binding ................. 2 .. Suggest repair or replacement.
Connector broken ........ A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ ( 2) Require replacement.
Insulation damaged,
conductors exposed ..... A .. Require repair or replacement.
Insulation damaged,
conductors not exposed . 1 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Motor runs continuously . A ......... Require or replacement.
Power antenna noisy ..... 2 .. Suggest repair or replacement.
Sticking ................ 2 .. Suggest repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of
specification.









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BATTERIES
Proper operation of any electrical system or component can be
affected by battery condition. The battery(ies) must meet or exceed