1999 DODGE RAM check engine

With Rear Unit ..................... 10.0 ............... 46.0
Ford Motor Co.
"E" Series
With Rear Unit ..................... 13.0 ............... 64.0
Without Rear Unit ................... 9.0 ............... 44.0
Expedition & Navigator ................ (2) ................ ( 2)
Explorer & Mountaineer ................ 7.0 ............... 30.0
F150/F250 Pickup ...................... 9.0 ............... 32.0
F250HD/F350 Pickup .................... 9.0 ............... 32.0
Ranger ................................ 7.0 ............... 30.0
Villager
With Rear Unit ..................... 11.0 ............... 56.0
Without Rear Unit ................... 7.0 ............... 32.0
Windstar
With Rear Unit ..................... 13.0 ............... 56.0
Without Rear Unit ................... 9.0 ............... 44.0
General Motors
"C" & "K" Series
Pickup & Sierra ..................... 8.0 ............... 32.0
Crew Cab & Utility .................. 8.0 ............... 36.0
Suburban, Tahoe & Yukon
With Rear Unit ..................... 11.0 ............... 64.0
Without Rear Unit ................... 8.0 ............... 36.0
"G" Series
With Rear Unit ..................... 11.0 ............... 78.0
Without Rear Unit ................... 8.0 ............... 48.0
"J" Series ............................ 3.4 ............... 21.0
"L" & "M" Series
With Rear Unit ..................... 11.0 ............... 48.0
Without Rear Unit ................... 8.0 ............... 32.0
"P" Series ............................ 8.0 ................ ( 2)
"S" & "T" Series
2.2L ................................ 9.0 .......... 30.0-32.0
4.3L ................................ 8.0 .......... 30.0-32.0
"U" Series
With Rear Unit ..................... 11.0 ............... 46.0
Without Rear Unit ................... 8.0 ............... 32.0
Jeep
Cherokee .............................. 8.1 ............... 20.0
Grand Cherokee ........................ 5.8 ............... 24.0
Wrangler .............................. 8.1 ............... 20.0
( 1) - Total system capacity, unless otherwise noted. Refer to
underhood A/C specification label in engine compartment for
specified oil type.
( 2) - Refrigerant oil and/or refrigerant capacity not available from
manufacturer. Refer to underhood A/C specification label in
engine compartment.









\









\









\









\









\









\









\







REFRIGERANT OILS
* PLEASE READ THIS FIRST *
NOTE: Use ONLY the specified oil for the A/C system or compressor.
Always check the underhood A/C specification label or A/C
compressor label before adding refrigerant oil to A/C
compressor/system.
NOTE: For compressor applications, see COMPRESSOR APPLICATIONS &
BODY DESIGNATIONS. DO NOT exceed A/C system refrigerant oil
capacity when servicing system. See CAPACITIES.

5) Once compressor shaft nut is tightened, check air gap
between clutch plate and pulley surface in at least 4 places. Readjust
air gap if necessary. Install A/C compressor. Evacuate and charge
system. Perform leak test. Ensure A/C system is operating properly.
6) 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
Shaft seal is not serviceable. If excessive oil is present on
pulley and plate friction surfaces or on compressor shaft nose area,
replace compressor.
ZEXEL ROTARY VANE
CLUTCH ASSEMBLY
NOTE: Discharging A/C system and removing refrigerant lines from
compressor is not necessary to service clutch assembly.
Removal
1) Loosen tensioner and remove drive belt from pulley.
Disconnect clutch electrical connector. Remove compressor mounting
bolts. With refrigerant lines connected lift compressor upward and
forward. Install one front mounting bolt through bottom rear
compressor mounting ear. Tighten bolt so compressor is supported by
mounting bracket.
2) Using Clutch Drive Plate Holder (SA9510AC), remove clutch\
drive plate center bolt. Insert Clutch Drive Plate Remover Sleeve
(SA9506AC) into center of drive plate. Install remover bolt. While
holding clutch remover sleeve, tighten remover bolt and remove drive
plate and shims.
3) Remove pulley external snap ring. Position Puller Center
Adapter (SA9149AC-2) over end of compressor shaft. Attach 3-jaw puller\
to back of pulley. Tighten puller bolt against pulley center adapter
and remove pulley. Remove clutch coil screws. Disconnect clutch coil
wire. Remove clutch coil.
Installation
1) Install coil in original position. Ensure electrical
connector is aligned with indent in front of compressor head. Tighten
screws to 44 INCH lbs. (5 N.m). Place Drive Plate Installer (SA9149AC\
-
3) and thrust bearing on installation bolt and insert through center
of pulley. Finger-tighten pulley installation bolt into compressor
shaft.
2) Finger-tighten nut on installation bolt to align pulley to
compressor. Hold end of bolt and tighten nut until pulley bottoms on
compressor. Loosen nut and remove installation bolt, thrust bearing
and drive plate installer. Install snap ring with tapered side out.
3) Install thrust bearing on installation bolt and insert
through clutch drive plate. Place original shims on installation bolt.
Thread bolt into compressor shaft. Hold end of bolt and tighten nut
until clutch drive plate bottoms out. Loosen nut and remove
installation bolt and thrust bearing. Install center bolt and tighten
to 115 INCH lbs. (13 N.m) using clutch drive plate holder.
4) Using a feeler gauge, measure air gap between drive plate
and pulley. Air gap should be 0.018-0.030" (0.46-0.76 mm). If air gap
is not as specified, add or remove shims as necessary. Install
compressor onto mounting bracket. Tighten front bolts to 36 ft. lbs.

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

Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - Refer to manufacturer's diagnostic trouble code
procedure and require repair or replacement of
affected component(s).
( 2) - Determine cause and correct prior to repair or
replacement of part.
( 3) - Determine source of contamination, such as engine coolant,
fuel, metal particles, or water. Require repair or
replacement. Check for accepted cleaning procedure.
( 4) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable.









\









\









\









\









\









\









\


COOLANT
COOLANT INSPECTION








\









\









\









\









\









\









\


Condition Code Procedure
Acidity (pH) incorrect .. 1 ........... Suggest correction or
replacement.
Contaminated ............ B ...... ( 1) Require replacement or
recycling. Further
inspection required.
Level incorrect ......... B .......... ( 2) Require filling to
proper level.
Maintenance intervals ... 3 ........ ( 3) Suggest replacement.
Mixture incorrect ....... B ........... Require correction or
replacement.
Type incorrect .......... B ............ Require replacement.
( 1) - Determine source of contamination and require correction
prior to coolant replacement.
( 2) - Determine source of incorrect level and suggest repair.
( 3) - The system should be drained and/or flushed and
refilled with correct coolant according to OEM
recommended service interval and procedures.









\









\









\









\









\









\









\


COOLING FAN BLADES
COOLING FAN BLADE INSPECTION








\









\









\









\









\









\









\


Condition Code Procedure
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
functioning ............ A ... Require repair or replacement
of hardware.

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

control panel and blower motor.
Fig. 3: Identifying Blower Motor Switch Connector Terminals (Typical)\
Courtesy of Chrysler Corp.
Rear (Durango)
1) Disconnect negative battery cable. Remove rear blower
motor switch located in headliner. See BLOWER MOTOR SWITCH (REAR)
under REMOVAL & INSTALLATION. Disconnect rear blower motor switch
connector. Using an ohmmeter, check continuity between rear blower
motor switch connector Black wire and ground. If continuity exists, go
to next step. If continuity does not exist, repair open in Black wire
between rear blower motor switch connector and ground connector
located at left rear of vehicle body.
2) Place blower motor switch knob to any position except OFF.
Using an ohmmeter, check for continuity between rear blower motor
switch connector Black wire and Black/Light Blue wire, and
Black/Orange wire and Dark Green wire while rotating blower motor
switch.
3) If continuity does not exist at any terminal, replace
faulty blower motor switch. If continuity exists as specified, check
for open in circuits between blower motor switch and blower motor
resistor. Also check for an open in circuit between blower motor
switch connector and blower motor relay.
CLUTCH CYCLING PRESSURE SWITCH
Dakota & Ram Pickup
1) Locate clutch cycling pressure switch on side or top of
A/C accumulator. Ensure clutch cycling pressure switch is properly
installed on A/C accumulator fitting. Ensure system pressure is
correct. See A/C SYSTEM PERFORMANCE test.
2) Start and run engine with A/C on. If clutch cycles, turn
engine off and disconnect negative battery cable. Disconnect clutch
cycling pressure switch connector. Place a jumper wire across
terminals of clutch cycling pressure 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
above 38 psi (2.7 kg/cm
) on Dakota; 43 psi (3.0 kg/cm) on Ram
Pickup. Continuity should not exist when suction pressure reading
drops below 20.5 psi (1.4 kg/cm
) on Dakota; 25 psi (1.8 kg/cm) on
Ram Pickup. If switch is okay, test and repair clutch control circuit
as needed. If switch is not okay, replace faulty clutch cycling
pressure switch.
ELECTRONIC CYCLING CLUTCH SWITCH
Durango
1) Locate electronic cycling clutch switch on thermal
expansion valve in engine compartment. Ensure system pressure is
correct. See A/C SYSTEM PERFORMANCE test. Ensure low pressure cut-out
switch and high pressure cut-out switch are working properly. See
LOW PRESSURE CUT-OUT SWITCH TEST and HIGH PRESSURE CUT-OUT SWITCH
test.
2) Disconnect negative battery cable. Disconnect electronic
cycling clutch switch and high pressure cut-out switch connectors.
Using an ohmmeter, check for continuity in Light Green/White wire
between electronic cycling clutch switch and high pressure cut-out
switch. If continuity exists in Light Green/White wire, go to next
step. If continuity does not exist in Light Green/White wire, repair
wire as necessary.
3) Disconnect low pressure cut-out switch connector. Using an
ohmmeter, check for continuity in Dark Blue/Yellow wire between
electronic cycling clutch switch and low pressure cut-out switch. If
continuity exists in Dark Blue/Yellow wire, go to next step. If
continuity does not exist in Dark Blue/Yellow wire, repair wire as
necessary.
4) Connect low pressure cut-out switch and high pressure cut-
out switch connectors. Connect negative battery cable. Turn ignition
on. Using voltmeter, check for battery voltage at electronic cycling
clutch switch connector terminal No. 2 (White wire). If battery
voltage exists, go to step 6).
5) If battery voltage does not exist, check fuse No. 7 (15-
amp) at junction block located at bottom left of instrument panel. If
fuse is okay, check for short or open in White wire between electronic
cycling clutch switch connector and fuse No. 7 (15-amp) at junction
block.
6) Connect electronic cycling clutch switch connector. Ensure
ambient temperature is between 68-90
F (20-30C). Start engine and
turn A/C on. If compressor clutch cycles 2-3 times per minute, replace
faulty electronic cycling clutch switch. If compressor clutch does not
cycle, check PCM for proper operation. See appropriate G - TESTS
W/CODES article in ENGINE PERFORMANCE section.
HIGH PRESSURE CUT-OUT SWITCH
1) Locate high pressure cut-out switch on compressor
discharge line, near compressor. Ensure system pressure is correct.
See A/C SYSTEM PERFORMANCE test. Disconnect negative battery cable.
Disconnect high pressure cut-off switch connector.
2) Using an ohmmeter, check for continuity between switch
terminals. If continuity exists, test and repair clutch control
circuit as needed. If continuity does not exist, replace faulty
switch.
LOW PRESSURE CUT-OUT SWITCH TEST
Durango

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.