1999 DODGE RAM instrument panel

from housing. To install, reverse removal procedure. Install new "O"
rings to A/C fittings. Evacuate and charge A/C system.
Removal & Installation (Durango - Rear Evaporator Core)
1) Disconnect negative battery cable. Discharge A/C system,
using approved refrigerant recovery/recycling equipment. Remove
headliner from passenger compartment of vehicle. Remove sun visors and
sun visor arm supports.
2) Remove coat hooks, overhead assist handle and dome light.
If equipped, remove overhead console. Remove air outlet bezel from
rear A/C-heater assembly. Remove rear blower motor switch. Remove
upper liftgate opening trim. Disengage "A", "B", "C", and "D" pillar
trim as necessary to prevent trim panel interference.
3) Move second and third row seats to cargo position. Move
front seats to full recline position. Remove headliner fasteners.
Carefully bow headliner and remove through lift gate opening.
4) Disconnect "B" pillar drain hoses from "Y" fittings.
Disconnect "B" pillar refrigerant lines and plug or cover all openings
in A/C system. Remove lower A/C-heater assembly cover. Remove screws
securing refrigerant tube and retaining strap to right side of upper
housing cover. Remove evaporator core. To install, reverse removal
procedure. Install new "O" rings to A/C fittings. Evacuate and charge
A/C system.
Removal & Installation (Ram Pickup - Front)
1) Remove and disassemble A/C-heater housing. See
A/C-HEATER ASSEMBLY . Separate halves of A/C-heater housing and remove
top half. Remove evaporator or heater core from housing.
2) To install, reverse removal procedure. Install new "O"
rings to A/C fittings. Evacuate and charge A/C system. Fill cooling
system. On 5.9L diesel engine, engine is equipped with a one-way check
valve. DO NOT run engine while filling cooling system. Fill engine
with engine turned off.
INSTRUMENT PANEL
Removal & Installation (Dakota & Durango)
1) Disconnect negative battery cable. Disable air bag system.
See AIR BAG SYSTEM SAFETY article. Place front wheels in straight-
ahead position. Remove sill trim from both doorways. Remove kick panel
covers from both sides of vehicle. Remove mounting screws for hood
release handle.
2) Remove steering column trim panel and support bracket.
Remove tilt steering column lever (if equipped). Remove upper and
lower shrouds from steering column. Unplug driver's side air bag
module. Loosen multifunction switch wiring harness connector screw and
disconnect from switch. Screw will remain in connector.
3) Disconnect PRNDL cable. Disconnect shift cable from
steering column. Remove steering coupler lock pin. Remove toe plate
retaining screws. Remove steering column mounting bolts and remove
steering column from vehicle.
4) Remove screw from bulkhead wiring harness connector and
disconnect. Disconnect 2 body wiring harness connectors located next
to bulkhead connector. Disconnect 3 wiring harness connectors, from
junction block, located nearest to dash panel. Disconnect brake light
switch connector. Disconnect Rear Wheel Anti-Lock (RWAL) brake module
(if equipped), located near steering column support brackets.
5) Disconnect plastic retainer clip from parking brake
linkage rod, located at back of parking brake release handle. Remove
rod end from parking brake handle. Remove instrument panel center
support bracket. Unplug vacuum harness connector located at left end
of A/C-heater housing. Disconnect Air Bag Control Module (ACM)
connector.

6) Remove glove box. Reach through glove box opening and
disconnect antenna coaxial cable connector. Disconnect blower motor
connector located above glove box opening, near support brace for A/C-
heater housing. Disconnect radio ground strap. Loosen instrument panel
roll down bracket bolts about 2 turns, located at lower corners on
both sides of instrument panel. Remove 5 screws across top of dash
panel at base of windshield, removing center screw last.
7) Roll down instrument panel and install a temporary support
hook that is about 18" (457 mm) in length. Install hook from center
hole in instrument panel to center hole of dash panel. Pull lower
instrument panel outward until both roll down bracket bolts are in
slotted roll down position. Instrument panel should now be supported
and away from firewall.
8) Disconnect 2 door harness connectors, located on a bracket
near right end of instrument panel. Disconnect blower motor resistor.
Disconnect temperature control cable from A/C-heater housing and
remove from housing. See Fig. 5. Disconnect demister duct flexible
hose from A/C-heater housing.
9) Ensure instrument panel is free and clear for removal.
With the aid of an assistant, remove temporary support hook. Lift
instrument panel off of roll down bracket bolts and remove from
vehicle.
10) To install, reverse removal procedure. Ensure all wiring
and hoses are clear and not pinched. Tighten bolts and nuts to
specification. See TORQUE SPECIFICATIONS . Enable air bag system. See
AIR BAG SYSTEM SAFETY article.
Removal & Installation (Ram Pickup)
1) Disable air bag system. See AIR BAG SYSTEM SAFETY article.
Disconnect negative battery cable. Drain cooling system. Remove left
and right kick panel trim. Remove 5 screws and knee bolster/steering
column cover. Remove hood release and parking brake release handle
screws from lower instrument panel support. Remove 6 screws and
instrument panel support. Disconnect air bag connector at lower left
corner of instrument panel.
2) Pull PRNDL cable and twist to remove from position arm.
Push tab on bottom of cable retainer upward, then squeeze sides to
remove retainer from column. Remove tilt lever (tilt column only).
Remove both upper and lower shrouds from column. Remove lower fixed
column shroud. Loosen multifunction switch connector screw. Screw will
remain in connector.
3) Remove remaining steering column electrical connectors.
Remove air bag wiring harness from steering column wiring trough.
Remove wiring trough from steering column. Remove 3 toe plate nuts and
washers.
4) Remove 2 nuts and washers attaching steering column
bracket to instrument panel steering column support bracket. Allow
column to lower and rest on seat. Remove 2 screws from bottom of Air
Bag Control Module (ACM) cover. Remove 4 screws holding ACM to
transmission tunnel.
5) Disconnect wiring at ACM. Disconnect instrument panel left
side wiring connectors. Remove screw holding brake release to bottom
of instrument panel. Disconnect instrument panel right side wiring
connectors, which includes 2 connectors attached to A/C-heater
assembly housing, courtesy light connector, antenna cable and 2 body
connectors. Disconnect vacuum harness from A/C-heater system.
6) Remove 5 screws holding instrument panel to dash. Loosen
lower instrument panel pivot bolts. Roll instrument panel downward.
Remove instrument panel from vehicle.
7) To install, reverse removal procedure. Ensure all wiring
and hoses are clear and not pinched. Tighten bolts and nuts to
specification. See TORQUE SPECIFICATIONS . Enable air bag system. See
AIR BAG SYSTEM SAFETY article.

TEMPERATURE CONTROL CABLE R & I
Removal (Dakota & Durango)
Disconnect negative battery cable. Disconnect but DO NOT
remove instrument panel. See INSTRUMENT PANEL. Disconnect temperature
control cable from A/C-heater control panel. Disconnect temperature
control cable from flag retainer located at top of A/C-heater assembly
housing. See Fig. 7. Remove temperature control cable self-adjuster
clip and temperature control cable.
Installation
1) Before installing temperature control cable, ensure that
self-adjuster clip is positioned as indicated. See Fig. 8.
Measurements must be made with cable end bottomed against flag
retainer on A/C-heater control panel end of cable housing.
2) Measure distance between center of self-adjusting clip and
end of cable flag retainer. If distance is not as specified, adjust
self-adjuster clip. To complete installation, reverse removal
procedure.
Fig. 7: Removing Control Cable Flag From Receiver (Typical)
Courtesy of Chrysler Corp.
Fig. 8: Adjusting Temperature Control Cable (Dakota & Durango)
Courtesy of Chrysler Corp.

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


D - A D JU STM EN TS - C NG & G ASO LIN E

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - On-Vehicle Adjustments - Trucks & RWD Vans - CNG & Gas
Dakota, Durango, Ram Pickup, Ram Van, Ram Wagon
ENGINE MECHANICAL
Before performing any on-vehicle adjustments to fuel or
ignition systems, ensure engine mechanical condition is okay.
VALVE CLEARANCE
NOTE: All engines use hydraulic lifters. No adjustments are
required.
IGNITION TIMING
On all models, ignition timing is controlled by Powertrain
Control Module (PCM). Ignition timing is nonadjustable. DO NOT attempt\
to adjust ignition timing by rotating distributor.
NOTE: On Dakota 3.9L, 5.2L and 5.9L, Durango, Ram Pickup, Ram Van
and Ram Wagon, if distributor is rotated, fuel system
synchronization will be changed. If distributor is removed or
rotated, check fuel system synchronization. See procedures
under FUEL SYSTEM SYNCHRONIZATION under FUEL SYSTEM.
FUEL SYSTEM
FUEL SYSTEM SYNCHRONIZATION
NOTE: Fuel system synchronization is controlled by position of the
distributor. Rotating distributor WILL NOT change ignition
timing, but will change fuel system synchronization. Fuel
system synchronization should be checked anytime distributor
is removed or rotated.
Dakota 3.9L, 5.2L & 5.9L, Durango, Ram Pickup, Ram Van & Ram
Wagon
1) Connect scan tool to Data Link Connector (DLC). DLC is
located below driver's side of instrument panel, near steering column.
See Fig. 1 , 2 or 3.
2) Using scan tool manufacturer's instructions, access SET
SYNC display on scan tool. Following scan tool displays, start engine.
Warm engine to normal operating temperature. Vehicle must be in closed
loop. With engine idling, if scan tool displays IN RANGE along with
0
, this indicates correct distributor location. The degree reading
displayed on scan tool indicates the fuel synchronization, not
ignition timing.
3) If scan tool display is correct, shut engine off. Remove
scan tool. If scan tool does not display IN RANGE along with 0
, go to
next step.
4) If scan tool displays a plus (+) or minus (-) sign next\
to
the degree number, and/or the degree number displayed is not zero,
loosen but DO NOT remove distributor hold-down bolt.
5) Rotate distributor until scan tool displays IN RANGE.
Continue to rotate distributor until a reading as close as possible to

2) Disconnect vacuum line at PCV valve located in valve
cover. Install .185" fixed orifice Air Metering Fitting (6714) into
disconnected vacuum line in place of PCV valve.
3) Disconnect purge vacuum hose from passenger's side front
corner of throttle body, next to MAP sensor. Place cap on vacuum hose
fitting on throttle body.
4) Connect scan tool to Data Link Connector (DLC) located
below driver's side of instrument panel, near steering column. See
Fig. 1, 2 or 3.
5) Start engine and warm engine to normal operating
temperature. Using scan tool manufacturer's instructions, select
SYSTEM TEST and then access the MINIMUM AIRFLOW display on scan tool.
When accessed, scan tool will count down to stabilize idle RPM and
display minimum airflow idle RPM. Minimum airflow idle RPM should be
500-900 RPM.
6) Shut engine off. If minimum airflow idle RPM is correct,
throttle body is okay. Go to next step. If minimum airflow idle RPM is
not within specification, using approved cleaner, clean throttle body
and recheck minimum airflow idle RPM. If correct minimum airflow idle
RPM cannot be obtained, replace throttle body. Go to next step.
7) Remove air metering fitting. Reinstall vacuum hoses as
necessary. Reinstall air duct on throttle body. Remove scan tool.
Ram Pickup 8.0L
Throttle body minimum airflow cannot be checked on this
application.
THROTTLE POSITION SENSOR
NOTE: Throttle Position (TP) sensor is nonadjustable. Use following\
procedure to check TP sensor calibration. For complete
testing of TP sensor and wiring circuit, see SELF-DIAGNOSTICS
- JEEP, TRUCKS & RWD VANS article.
Dakota, Ram Pickup, Ram Van & Ram Wagon
1) Remove components for access to electrical connector at TP
sensor mounted on throttle body. With electrical connector installed
on TP sensor, turn ignition on with engine off. DO NOT start engine.
2) Using digital volt-ohmmeter, measure voltage at center
terminal on electrical connector for TP sensor with throttle valve
closed (idle position). Voltage should be greater than .35 volt, but
less than .90 volt.
3) Slowly open throttle to full throttle and note voltage
reading. Voltage should smoothly increase to less than 4.50 volts.
Replace TP sensor if voltage is not within specification.

AIR B AG R ESTR AIN T S YSTE M
1999 D odge P ic ku p R 1500
1999 AIR BAG RESTRAINT SYSTEMS
DaimlerChrysler Corp.
Dodge: Ram Pickup
DESCRIPTION & OPERATION
* PLEASE READ THIS FIRST *
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all WARNINGS and SERVICE PRECAUTIONS.
Supplemental Restraint System (SRS) is designed to work in
conjunction with seat belts. SRS helps to reduce the risk or severity
of serious injury during a front-end collision. Driver-side air bag is
stored in a module in steering wheel hub. All models are equipped with
passenger-side air bags. Passenger-side air bag is stored in the
instrument panel, above glove box. All air bags are covered by a pad
bearing the air bag SRS logo.
Air bag(s) inflate and deflate within 1/10th of a second of
impact sensor switches closing. This creates a cushion of air between
driver and steering wheel and passenger and instrument panel.
System consists of an AIR BAG warning light, clockspring,
driver-side and passenger-side air bag modules, Air Bag Control Module
(ACM), one impact sensor (located inside ACM) and an energy reserve
capacitor. The ACM monitors system, stores fault codes (messages) and
provides information to AIR BAG warning light and Data Link Connector
(DLC). When a malfunction occurs, a fault code is stored and AIR BAG
warning light is activated for more than 12 seconds.
When impact sensor registers sufficient deceleration force
during a front-end collision, an electrical charge is sent from ACM to
air bag module inflator via the clockspring. Inflator actuates and
produces nitrogen gas, which inflates air bag(s).
AIR BAG WARNING LIGHT
Whenever ignition switch is in RUN or START position, AIR BAG
warning light on instrument panel will illuminate for 6-8 seconds and
then turn off. This signifies ACM has checked the system and found
that it is functioning properly. If AIR BAG warning light illuminates
for 12 seconds or more, stays on all the time or does not come on, a
system malfunction exists and trouble code will be stored.
IMPACT SENSOR
All models have one impact sensor located inside ACM. Impact
sensor is an accelerometer that measures deceleration. During a front-
end collision, a signal is sent that completes an electrical circuit
to inflators. Inflators actuate and produce nitrogen gas, which
inflates each air bag. Impact sensor is calibrated for a specific
vehicle and react to severity and direction of vehicle impact.
AIR BAG MODULE
WARNING: DO NOT attempt to disassemble air bag modules. Air bag
modules are not serviceable.
Driver-Side
Air bag module is mounted on front face of steering wheel. A

protective cover is fitted to front of air bag module bearing the SRS
air bag logo. Air bag module contains air bag cushion, inflator and
supporting components. Air bag module is a sealed unit and is not
serviceable. The module inflator assembly produces nitrogen gas to
fill air bag cushion when a small amount of current from ACM is
applied to the ignitor assembly. Gas pressure builds and discharges
from inflator through a diffuser and screen assembly, forcing steering
wheel cover to burst along its seams until air bag is fully inflated.
Once air bag cushion is fully inflated, gas escapes from bag through
vents, away from driver.
Passenger-Side
Air bag module is mounted to instrument panel mounting
bracket. Module is covered by a protective door bearing the SRS air
bag logo. When supplied an electrical signal, inflator will discharge
argon gas directly into air bag. When air bag inflates, protective
door will pivot aside allowing air bag to deploy.
AIR BAG CONTROL MODULE (ACM)
ACM is located under instrument panel, on transmission
tunnel. Impact sensor, energy reserve capacitor and On-Board
Diagnostics (OBD) are an integral part of ACM. ACM monitors critical
input and output circuits within air bag system, ensuring they are
operating correctly. Some circuits are tested continuously; others are
checked only under certain conditions. ACM provides information about
air bag system through AIR BAG warning light and Data Link Connector
(DLC). When diagnostic trouble code (fault message) is stored, AIR B\
AG
warning light will be activated for 12 seconds or more.
DATA LINK CONNECTOR (DLC)
DLC is located under left side of instrument panel, left of
steering column. DLC is used to access SRS on-board diagnostics.
CLOCKSPRING
Clockspring connects air bag module to steering column
wiring, completing air bag system circuit. See Fig. 1. Inside
clockspring is a flat, ribbon-like tape of conductive material, which
winds and unwinds with steering wheel movement. Clockspring is the
most fragile part of air bag system. Clockspring must be centered
properly to allow 1 1/2 steering wheel turns in either direction. If
clockspring is not centered properly, it can break from stretching or
fatigue.
Fig. 1: Identifying Clockspring Assembly
Courtesy of DaimlerChrysler Corp.