1999 DODGE RAM Service Repair Manual

trunk release drain bolt spare tire location auxiliary battery location spark plugs tow bar

Page 89 of 1691

DODGE RAM 1999 Service Repair Manual Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket holes elongated,
affecting performance .. A .. Require repair or replacement.
Bracket holes elongate

Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket holes elongated,
affecting performance .. A .. Require repair or replacement.
Bracket holes elongated,
not affecting
performance ............ .. ........ No service suggested or
required.
Bracket loose, affecting
performance ............ A .. Require repair or replacement.
Bracket loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket missing ......... C ............ Require replacement.
Connection damaged ...... B .. Require repair or replacement.
Contaminated, affecting
performance ............ A ............ Require replacement.
Corroded internally ..... 1 ............ Suggest replacement.
Dessicant bag
deteriorated ........... A ........ (1) Require replacement.
Further inspection required.
Dessicant at the end of
its useful life
(saturated
with moisture) ......... 1 .. Suggest repair or replacement.
Filter screen torn ...... A .. Require replacement of screen.
Fitting damaged ......... B .. Require repair or replacement.
Fusible plug leaking .... A .... Require replacement of plug.
Inoperative ............. A ........... ( 2) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Pressure relief device
leaking ................ A . Require replacement of pressure
relief device.
Restricted .............. A .. Require repair or replacement.
Sight glass no longer
transparent ............ 2 ... Suggest replacement of drier.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Tubing connection
leaking ................ A .. Require repair or replacement.
( 1) - Inspect system to determine effects of dessicant bag
deterioration.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.
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WATER PUMPS (ELECTRIC AUXILIARY)
WATER PUMP (ELECTRIC AUXILIARY) 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.

Page 90 of 1691

DODGE RAM 1999 Service Repair Manual Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted,
affecting performance ..

Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted,
affecting performance .. A ........... (1) Require repair or
replacement.
Connector melted, not
affecting performance .. 2 ........... ( 1) Suggest repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ ( 2) Require replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 ............ Suggest 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.
Vibration ............... 1 .. Suggest 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) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.
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WIRING HARNESSES AND CONNECTORS
WIRING HARNESS AND CONNECTOR INSPECTION\
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Condition Code Procedure
Application incorrect ... B .. 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.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Circuit open ............ A .. Require repair or replacement.
Circuit resistance
(voltage drop) out of

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DODGE RAM 1999 Service Repair Manual specification .......... A .. Require repair or replacement.
Circuit shorted ......... A .. Require repair or replacement.
Connector melted,
affecting performance .. A ........... (1) Re

Page 92 of 1691

DODGE RAM 1999 Service Repair Manual
A/C -H EA TE R S YSTE M

1999 D odge P ic ku p R 1500
1999 MANUAL A/C-HEATER SYSTEMS
CHRYSLER
Dakota, Durango & Ram Pickup
SPECIFICATIONS
SPECIFICATIONS��

A/C -H EA TE R S YSTE M

1999 D odge P ic ku p R 1500
1999 MANUAL A/C-HEATER SYSTEMS
CHRYSLER
Dakota, Durango & Ram Pickup
SPECIFICATIONS
SPECIFICATIONS\
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Application Specification
Compressor Type .............................. Sanden SD-7H15 7-Cyl.
Compressor Belt Tension ........................................ ( 1)
Refrigerant (R-134a) Capacity
With Rear A/C Unit ....................................... 30 ozs.
Without Rear A/C Unit .................................... 28 ozs.
System Oil Capacity
Dakota & Ram Pickup ................................. ( 2) 8.1 ozs.
Durango
With Rear A/C Unit ................................. ( 2) 8.0 ozs.
Without Rear A/C Unit .............................. ( 2) 5.5 ozs.
System Operating Pressures ( 3)
High Side ......................... 190-220 psi (13.4-15.5 kg/cm
)
Low Side .............................. 32-40 psi (2.2-2.8 kg/cm)
( 1) - Dynamic tensioner automatically adjusts belt. Tension is okay if
indicator is within marked limits on belt tensioner.
( 2) - Use SP-20 PAG refrigerant oil.
( 3) - Measured at ambient air temperature of 80
F (27C).\
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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.
CAUTION: When battery is disconnected, radio will go into anti-theft
protection mode. Obtain radio anti-theft protection code from
owner prior to servicing vehicle.
DESCRIPTION
These systems are a blend-air type. Outside air enters
through a cowl at base of the windshield and flows through a plenum
chamber into blower housing. Airflow velocity is controlled by blower
speed selector switch. Air flows across evaporator and is directed by
a blend-air door to go either through or by-pass the heater core.
On Dakota and Durango, temperature control cable operates
blend-air door and allows immediate control of outlet air temperature.
It also controls operation of recirculation door. On Ram Pickup,
temperature is regulated by a blend-air servo motor controlled from
A/C-heater control panel rotary temperature dial. On all models, mode
selector switch controls vacuum-operated doors to direct conditioned
air to selected outlets.
Durango may also be equipped with an optional rear A/C unit.
The rear A/C unit consists of a blower motor and evaporator. It will
only operate while the front A/C is on. The optional rear A/C-heater
unit is controlled using fan and temperature switches.

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DODGE RAM 1999 Service Repair Manual OPERATION
CONTROL PANEL
Blower Motor Switch
Fan speed is controlled with a rotary switch. On front A/C-
heater systems, there are 4 different fan speed settings.

OPERATION
CONTROL PANEL
Blower Motor Switch
Fan speed is controlled with a rotary switch. On front A/C-
heater systems, there are 4 different fan speed settings. Low, medium-
low, medium-high, and high. On rear A/C-heater systems, there are 3
different fan speed settings. Low, medium, and high.
Mode Control Knob
Mode rotary switch is used to change direction of air flow.
There are 7 different modes of operation: recirculation, panel with
A/C, floor/panel, panel without A/C (vent), floor, floor/defrost, and
defrost.
Temperature Control Knob
Temperature rotary switch controls temperature blend/air door
position by a cable on Dakota and Durango, and by vacuum actuator for
Ram Pickup. When cold temperature is selected, no air flows across
heater core. When hot temperature is selected, all air flows through
heater core. Temperature may vary by any setting between cold and hot.
CLUTCH CYCLING PRESSURE SWITCH
Dakota & Ram Pickup
Clutch cycling low pressure switch is mounted on a Schrader-
type valve fitting that is part of the accumulator. It is connected in
series with the high pressure cut-off switch and control panel,
between ground and PCM. Switch contacts open and close due to changes
in A/C system pressure. Opening and closing of switches will cause PCM
to turn compressor clutch on and off, regulating system pressure which
controls temperature of evaporator.
Clutch cycling low pressure switch contacts are normally open
when suction (low side) pressure drops below 25 psi (1.8 kg/cm
) on
Ram Pickup; 20.5 psi (1.4 kg/cm) on Dakota. Extreme cold weather will
also open contacts. When contacts are open, PCM will de-energize
compressor clutch relay, disengaging compressor clutch.
Clutch cycling pressure switch contacts will close when
suction (low side) pressure rises above 43 psi (3.0 kg/cm
) on Ram
Pickup or 36 psi (2.5 kg/cm) on Dakota. When contacts are closed, PCM
will energize compressor clutch relay, engaging compressor clutch.
ELECTRONIC CYCLING CLUTCH SWITCH
Durango
The electronic cycling clutch switch is mounted to Thermal
Expansion Valve (TXV), also referred to as an "H" valve, in engine
compartment. It provides evaporator temperature to the PCM. Using this
information, the PCM will cycle the compressor clutch to prevent
evaporator icing. The switch is used for the front evaporator only.
Electronic cycling clutch switch is connected in series with
mode control switch, high pressure cut-out switch, low pressure cut-
out switch, and PCM. The electronic cycling clutch switch opens when
refrigerant temperature is below about 37
F (2.8C) and will close
when refrigerant temperature is about 40F (4.4C).
FIXED ORIFICE TUBE
Dakota & Ram Pickup
The fixed orifice tube is located in outlet line of the
condenser. The orifice tube inlet and outlet ends have a screen to

Page 94 of 1691

DODGE RAM 1999 Service Repair Manual filter the refrigerant. The orifice tube is used to meter the flow of
liquid refrigerant into the evaporator core.
HIGH PRESSURE CUT-OUT SWITCH
High pressure cut-out switch is locate

filter the refrigerant. The orifice tube is used to meter the flow of
liquid refrigerant into the evaporator core.
HIGH PRESSURE CUT-OUT SWITCH
High pressure cut-out switch is located on compressor
discharge line, near compressor. On Dakota and Ram Pickup, it is
connected in series with the clutch cycling pressure switch and
control panel, between ground and PCM.
On Durango, it is connected in series with the electronic
cycling clutch switch, low pressure cut-out switch and control panel,
between ground and PCM. PCM controls compressor clutch operation.
On all models, when discharge pressure reaches 450-490 psi
(31.6-34.5 kg/cm
), high pressure cut-out switch interrupts A/C
request signal to PCM. PCM de-energizes compressor clutch relay,
disengaging compressor clutch. When discharge pressure drops to 270-
330 psi (23.2-19 kg/cm
) switch will close, thus restoring A/C request
signal to PCM.
HIGH PRESSURE RELIEF VALVE
High pressure relief valve is located on compressor manifold.
Valve vents system pressure if pressure is greater than 500-600 psi
(35.1-42.2 kg/cm
). Valve will reset when pressure decreases to 400
psi (28.1 kg/cm).
LOW PRESSURE CUT-OUT SWITCH OPERATION
Durango
Low pressure cut-out switch is located on suction line near
firewall. It is connected in series with the electronic cycling clutch
switch, high pressure cut-out switch and control panel, between ground
and PCM. PCM controls compressor clutch operation.
When discharge pressure reaches 10 psi (.7 kg/cm
), switch
interrupts A/C request signal to PCM. PCM de-energizes compressor
clutch relay, disengaging compressor clutch. When discharge pressure
increases to 13-27 psi (.9-1.9 kg/cm
), switch will close thus
restoring A/C request signal to PCM.
ADJUSTMENTS
TEMPERATURE CONTROL CABLE ADJUSTMENT
Dakota & Durango
1) Ensure temperature control cable housing and core are
connected at both A/C-heater control panel and A/C-heater assembly.
Ensure A/C-heater control panel is installed.
2) Rotate temperature control knob so that knob pointer is at
12 o'clock position. Pull temperature control knob straight out from
A/C-heater control panel until perimeter of knob (not knob pointer)
protrudes about .25" (6 mm) from face of A/C-heater control panel.
3) Rotate temperature control knob clockwise so that knob
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 A/C-heater control panel until perimeter of knob (not

Page 95 of 1691

DODGE RAM 1999 Service Repair Manual 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.
I

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

Page 96 of 1691

DODGE RAM 1999 Service Repair Manual operate engine at idle speed. With A/C compressor clutch engaged, note
air outlet temperature, compressor discharge pressure, and evaporator
inlet pressure. See appropriate A/C SYSTEM PERFORMANCE TEMP

operate engine at idle speed. With A/C compressor clutch engaged, note
air outlet temperature, compressor discharge pressure, and evaporator
inlet pressure. See appropriate A/C SYSTEM PERFORMANCE TEMPERATURE
SPECIFICATIONS and A/C SYSTEM PERFORMANCE PRESSURE SPECIFICATIONS
tables.
A/C SYSTEM PERFORMANCE TEMPERATURE SPECIFICATIONS (DAKOTA)
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Ambient Temp. F (C) Outlet Vent Temp. F (C)
70 (21) ..................................................... 38 (3\
)
80 (27) ..................................................... 44 (7\
)
90 (32) ..................................................... 48 (9\
)
100 (38) ................................................... 55 (13\
)
110 (43) ................................................... 64 (18\
)
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A/C SYSTEM PERFORMANCE TEMPERATURE SPECIFICATIONS (DURANGO)\
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Ambient Temp. F (C) Outlet Vent Temp. F (C)
70 (21) ..................................................... 48 (9\
)
80 (27) ..................................................... 48 (9\
)
90 (32) .................................................... 54 (12\
)
100 (38) ................................................... 59 (15\
)
110 (43) ................................................... 65 (18\
)
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A/C SYSTEM PERFORMANCE TEMPERATURE SPECIFICATIONS (RAM PICKUP)\
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Ambient Temp. F (C) Outlet Vent Temp. F (C)
70 (21) ................................................ 40-45 (5-7\
)
80 (27) .............................................. 55-60 (13-16\
)
90 (32) .............................................. 60-70 (16-21\
)
100 (38) ............................................. 70-75 (21-24\
)
110 (43) ............................................. 80-85 (27-29\
)
120 (49) ............................................. 85-90 (29-32\
)
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A/C SYSTEM PERFORMANCE PRESSURE SPECIFICATIONS (DAKOTA)\
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Ambient Temp. High Side Low SideF (C) psi (kg/cm) psi (kg/cm)
70 (21) .............. 160-200 (11.2-14.1) ....... 25-35 (1.8-2\
.5)
80 (27) .............. 190-220 (13.4-15.5) ....... 32-40 (2.2-2\
.8)
90 (32) .............. 200-240 (14.1-16.9) ....... 37-45 (2.6-3\
.2)
100 (38) ............. 220-260 (15.5-18.3) ....... 39-50 (2.7-3\
.5)
110 (43) ............. 250-300 (17.6-21.1) ....... 45-55 (3.2-3\
.9)
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A/C SYSTEM PERFORMANCE PRESSURE SPECIFICATIONS (DURANGO)\
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Ambient Temp. High Side Low SideF (C) psi (kg/cm) psi (kg/cm)
70 (21) .............. 100-150 (7.0-10.5) ........ 20-30 (1.4-2\
.1)
80 (27) .............. 135-185 (9.5-13.0) ........ 20-30 (1.4-2\
.1)
90 (32) .............. 170-220 (12.0-15.5) ....... 25-35 (1.8-2\
.5)
100 (38) ............. 210-255 (14.8-17.9) ....... 31-41 (2.2-2\
.9)
110 (43) ............. 245-295 (17.2-20.7) ....... 37-47 (2.6-3\
.3)
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