1999 DODGE RAM ESP

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

2) Ensure service hoses are equipped with valve core
depressor to match Schrader valve. If not, install special adapters
for this purpose. If the high-side service hose connector will not fit
on high-side Schrader valve, a special adapter must be used. See
SPECIAL VALVE CONNECTORS.
3) Ensure both manifold gauge set hand valves are closed.
Connect low-side service hose to low-side (suction) service valve, and\
finger tighten connections. Connect high-side service hose to high-
side (discharge) service valve, and finger-tighten connections.
NOTE: After test gauges are installed, test hoses must be purged of
all air before proceeding with testing.
PURGING TEST HOSES
1) Ensure high-side and low-side hoses are properly connected
to service valves, and all hose connections are tight. Place a clean
shop towel over end of center service hose.
2) Purge high-side test hose by opening hand valve on high-
side gauge for 3-5 seconds. This allows the system's refrigerant to
force air through test hoses and out of center service hose into the
shop towel. Immediately close high-side gauge hand valve.
3) Purge low-side test hose in the same manner using hand
valve of low-side gauge. Close hand valve after 3-5 seconds. Purging
of test hoses is now complete, and system is ready for testing.
NOTE: If manifold gauge set is to be used in conjunction with
refrigerant recovery/recycling equipment, use instructions
provided with the recovery/recycling equipment to properly
purge test hoses.
STABILIZING A/C SYSTEM
1) Once manifold gauge set is attached to system and test
hoses have been purged, the system is ready for testing. Place all
test hoses, gauge set and other equipment away from all moving parts
of engine.
2) Start engine, and turn A/C controls to maximum cooling
position (full cold or MAX A/C). Set blower on high speed. Open doors
and/or windows. Operate system for 5-10 minutes. System should now be
stabilized and ready for test readings.
PRESSURE-TEMPERATURE RELATIONSHIP
A refrigerant, when confined in an enclosed space, increases
in pressure as the temperature increases. Conversely, if the
temperature is lowered, the pressure also decreases.
Depending on temperature, a corresponding pressure will exist
in such an enclosed space. For example, at 70
F (21.1C) a gauge will
indicate about 71.0 psi (5.0 kg/cm). The R-134a PRESSURE- TEMPERATURE
RELATIONSHIP table shows this relationship.
R-134a PRESSURE-TEMPERATURE RELATIONSHIP









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Temperature F (C) ( 1) psi (kg/cm)
20 (-6.7) ................................................. 18 (1.3\
)
30 (-1.1) ................................................. 26 (1.8\
)
40 (4.4) .................................................. 35 (2.5\
)
50 (10.0) ................................................. 45 (3.2\
)
60 (15.6) ................................................. 57 (4.0\
)

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

connector terminal No. 14 (Light Green/Yellow wire). If voltage is
less than 10 volts, repair open in Light Green/Yellow wire. If voltage
is more than 10 volts, replace ACM.
4) If there are no potential causes for this DTC remaining,
ACM is assumed to be defective. Replace ACM. See
AIR BAG CONTROL MODULE (ACM) under REMOVAL & INSTALLATION.
5) Turn ignition off. Turn PAD switch to the ON position (if
equipped). Using an ohmmeter, check resistance at fused ignition
switch output RUN/START circuit between fuse No. 19 and ground. If
resistance is more than 5 ohms, replace fuse. If resistance is less
than 5 ohms, disconnect battery and wait 2 minutes before proceeding.
Disconnect ACM connector. Using an ohmmeter, check resistance between
ground and ACM connector terminal No. 14 (Light Green/Yellow wire). If\
resistance is less than 5 ohms, go to next step. If resistance is more
than 5 ohms, replace ACM and fuse No. 19.
6) Disconnect PAD switch. Using an ohmmeter, check resistance
between ground and ACM connector terminal No. 14 (Light Green/Yellow
wire). If resistance is less than 5 ohms, repair short to ground in
Light Green/Yellow wire and replace fuse No. 19. If resistance is more
than 5 ohms, replace fuse No. 19 located in junction block and go to
next step.
7) If there are no potential causes for this DTC remaining,
ACM is assumed to be defective. Replace ACM. See
AIR BAG CONTROL MODULE (ACM) under REMOVAL & INSTALLATION.
MISSING OR INVALID VIN MESSAGE
NOTE: Perform AIR BAG VERIFICATION TEST after
all repairs. 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. Due to manufacturer changes in wire
colors, use terminal identification whenever possible.
1) Using DRB, select ENGINE PCM. If DRB displays NO RESPONSE
from PCM, go to NO RESPONSE FROM POWERTRAIN CONTROL MODULE under
VEHICLE COMMUNICATIONS. If DRB does not display NO RESPONSE from PCM
and vehicle is a Club Cab (BE) model, go to next step. If vehicle is
not a Club Cab (BE model), go step 3).
2) Using DRB, select PASSIVE RESTRAINTS, AIRBAG AND MONITORS.
Select VIN type (7th digit of VIN; VIN 2 or 3 on Club Cab). If DRB
does not display PCM VIN: BE, replace Powertrain Control Module (PCM).\
If DRB displays PCM VIN: BE, replace ACM.
3) Using DRB, select PASSIVE RESTRAINTS, AIRBAG AND MONITORS.
Select VIN type (7th digit of VIN; VIN 6 on Standard Cab). If DRB does\
not display PCM VIN: BR, replace Powertrain Control Module (PCM). If
DRB displays PCM VIN: BR, replace ACM.
NO CCD COMMUNICATION
NOTE: Perform AIR BAG VERIFICATION TEST after
all repairs. 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. Due to manufacturer changes in wire
colors, use terminal identification whenever possible.
Using DRB, read active codes. If DRB displays NO CCD
COMMUNICATION as an active code, replace ACM. If DRB does not display
NO CCD COMMUNICATION as an active code, go to
REPAIRING STORED TROUBLE CODES .
NO CLUSTER CCD MESSAGE

NOTE: Perform AIR BAG VERIFICATION TEST after
all repairs. 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. Due to manufacturer changes in wire
colors, use terminal identification whenever possible.
1) Using DRB, select ELECRO/MECH CLUSTER (MIC). If DRB
displays NO RESPONSE FROM MIC, go to
NO RESPONSE FROM INSTRUMENT CLUSTER under VEHICLE COMMUNICATIONS. If
DRB does not display NO RESPONSE FROM MIC, go to next step.
2) Using DRB, select PASSIVE RESTRAINTS, AIRBAG, MONITORS,
AND WARNING LAMP STATUS to read lamp messages from cluster. If ACM
lamp request displays NO RESP, replace ACM. If ACM lamp request does
not display NO RESP, go to next step.
3) Disconnect battery and wait 2 minutes before proceeding.
Disconnect ACM 23-pin connector. Disconnect mechanical instrument
cluster Black connector "A". Go to next step.
4) Using an ohmmeter, check resistance between mechanical
instrument cluster Black connector "A" terminal No. 9 (White/Black
wire) and ACM connector terminal No. 22 (White/Black wire). Also,
check resistance between mechanical instrument cluster Black connector
"A" terminal No. 10 (Violet/Brown wire) and ACM connector terminal No.\
21 (Violet/Brown wire). Go to next step.
5) If resistance is less than 5 ohms on both circuits,
replace instrument cluster. If resistance is more than 5 ohms on both
circuits, repair open in CCD bus circuit(s).
PASSENGER SQUIB CIRCUIT OPEN
NOTE: Perform AIR BAG VERIFICATION TEST after
all repairs. 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. Due to manufacturer changes in wire
colors, use terminal identification whenever possible.
1) Disconnect battery and wait 2 minutes before proceeding.
Disconnect passenger-side air bag module. Connect a jumper wire
between passenger-side air bag module 2-pin connector terminals "A"
(Black/Yellow wire) and "B" (Dark Green/Yellow wire). Turn ignition
on. Reconnect battery. Using DRB, read active codes. If DRB displays
PASSENGER SIDE SQUIB SHORT, replace passenger-side air bag module. If
not, go to next step.
2) Remove jumper wire. Disconnect battery and wait 2 minutes
before proceeding. Disconnect ACM connector. Disconnect PAD switch 4-
pin connector. Using an ohmmeter, check resistance between passenger-
side air bag module 2-pin connector terminal "A" (Black/Yellow wire)
and PAD switch 4-pin connector (harness side) terminal No. 3
(Black/Yellow wire). If resistance is less than 5 ohms, go to next
step. If resistance is more than 5 ohms, repair open or high
resistance in Black/Yellow wire.
3) Using an ohmmeter, check resistance between PAD switch 4-
pin connector (harness side) terminal No. 3 (Black/Yellow wire) and
passenger-side air bag module 2-pin connector terminal "B" (Dark
Green/Yellow wire). If resistance is more than 5 ohms, repair open or
high resistance in Dark Green/Yellow wire. If resistance is less than
5 ohms, go to next step.
4) Using an ohmmeter, check resistance between PAD switch 4-
pin connector (harness side) terminals No. 2 (Violet/Yellow wire) an\
d
No. 4 (Dark Green/Yellow wire). Also, check resistance between PAD
switch 4-pin connector (harness side) terminals No. 1 (Brown/Yellow

colors, use terminal identification whenever possible.
1) If seat belt light is on, go to step 4). If seat belt
light is not on, go to next step.
2) Using DRB, select PASSIVE RESTRAINTS, AIRBAG AND MONITOR
DISPLAY. Read WARNING LAMP STATUS. If DRB does not display MIC S/B
LAMP STATE: OFF, replace instrument cluster. If DRB displays MIC S/B
LAMP STATE: OFF, go to next step.
3) If DRB displays ACM S/B LAMP REQUEST: OFF, replace ACM. If
DRB does not display ACM S/B LAMP REQUEST: OFF, replace instrument
cluster.
4) Using DRB, select PASSIVE RESTRAINTS, AIRBAG AND MONITOR
DISPLAY. Read WARNING LAMP STATUS. If DRB does not display MIC S/B
LAMP STATE: ON, replace instrument cluster. If DRB displays MIC S/B
LAMP STATE: ON, go to next step.
5) Using DRB, read WARNING LAMP STATUS. If DRB does not
display ACM S/B LAMP REQUEST: ON, replace instrument cluster. If DRB
displays ACM S/B LAMP REQUEST: ON, replace ACM.
REPAIRING VIN MESSAGE MISMATCH
NOTE: Perform AIR BAG VERIFICATION TEST after
all repairs. 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. Due to manufacturer changes in wire
colors, use terminal identification whenever possible.
1) Using DRB, select ENGINE (PCM). If DRB displays NO
RESPONSE FROM PCM, perform REPAIRING SHORT TO BATTERY under VEHICLE
COMMUNICATIONS. If DRB does not display NO RESPONSE FROM PCM, and
vehicle is a Club Cab (BE), go to next step. If DRB does not display
NO RESPONSE FROM PCM, and vehicle is a Standard Cab (BR), go to step
3).
2) Using DRB, select PASSIVE RESTRAINTS, AIRBAG AND MONITOR
DISPLAY. Select VIN type to identify 7th digit of VIN (VIN 2 or 3 is
for Club Cab; VIN B is for a Standard Cab). If DRB does not display
PCM VIN: BE, replace powertrain control module. If DRB displays PCM
VIN: BE, replace ACM.
3) Using DRB, select PASSIVE RESTRAINTS, AIRBAG AND MONITOR
DISPLAY. Select VIN type to identify 7th digit of VIN (VIN B is for a
Standard Cab). If DRB does not display PCM VIN: BE, replace powertrain
control module. If DRB displays PCM VIN: BE, replace ACM.
WARNING LAMP CIRCUIT OPEN/SHORTED
NOTE: Perform AIR BAG VERIFICATION TEST after
all repairs. 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. Due to manufacturer changes in wire
colors, use terminal identification whenever possible.
1) Using DRB, select MECHANICAL INSTRUMENT CLUSTER (MIC). If\
DRB displays NO RESPONSE FROM MIC, go to
NO RESPONSE FROM INSTRUMENT CLUSTER under VEHICLE COMMUNICATIONS. If
DRB does not display NO RESPONSE FROM MIC, go to next step.
2) Using DRB, select PASSIVE RESTRAINTS AIRBAG AND MONITOR
DISPLAY. Read WARNING LAMP status. If DRB does not display MIC BULB
STATE, replace instrument cluster. If DRB displays MIC BULB STATE, go
to next step.
3) If DRB does not display MIC DRIVER STATE OK, replace
instrument cluster. If DRB displays MIC DRIVER STATE OK, go to next

3) Using DRB, read stored codes. If DRB displays stored
codes, perform appropriate diagnostic test. If DRB does not display
any stored codes, system is operating properly at this time.
COMPONENT VERIFICATION TEST
Reconnect all previously disconnected components and
connectors. Turn ignition on (engine off). Fully operate system that
was malfunctioning. If system operates properly, repair is complete.
If system does not operate properly, go to appropriate diagnostic
test.
VEHICLE COMMUNICATIONS
VEHICLE COMMUNICATION PROBLEMS
NOTE: Use this test only when instructed to do so by another
diagnostic test. Due to manufacturer changes in wire
colors, use terminal identification whenever possible.
DRB Blank Screen
If DRB Screen is blank, disconnect DRB from data link
connector. Ensure good ground exists at data link connector terminal
No. 4 (Black/Tan wire). Ensure 12-volts exists at data link connector
terminal No. 16 (Pink wire). If 12-volts does not exist, check for
blown fuse No. 12 located in power distribution center. If no problems
can be found, try a different DRB cable and/or a different DRB.
No Response Condition
If no response condition from Air Bag Control Module (ACM)
exists, go to NO RESPONSE FROM AIR BAG CONTROL MODULE .
NO RESPONSE FROM AIR BAG CONTROL MODULE
NOTE: Perform COMPONENT VERIFICATION TEST under DIAGNOSTIC TESTS
after all repairs. 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. Due to manufacturer changes in
wire colors, use terminal identification whenever possible.
1) Remove and inspect fuse No. 19. If fuse is blown, go to
OPEN FUSED IGNITION SWITCH OUTPUT (RUN/START) CKT . If not, go to next
step.
2) Using a voltmeter, measure ignition switch output
RUN/START at fuse No. 19. See WIRING DIAGRAMS. If voltage is more than
10 volts, go to next step. If voltage is less than 10 volts, repair
open ignition switch output RUN/START circuit.
3) Turn ignition off and wait 2 minutes. Disconnect ACM
connector. Reinstall fuse No. 19. Turn ignition on (engine off). Using\
a voltmeter, check voltage at ACM connector terminal No. 14 (Light
Green/Yellow wire). If voltage is more than 10 volts, go to next step.
If voltage is less than 10 volts, repair open in Light Green/Yellow
wire.
4) Turn ignition off. Using DRB in ohmmeter mode, check
resistance at ACM connector terminal No. 4 (Black/Pink wire). If
resistance is more than 5 ohms, repair open in Black/Pink wire. If
resistance is less than 5 ohms, go to next step.
5) Turn ignition on (engine off). Using DRB in voltmeter
mode, check voltage at ACM connector terminal No. 21 (Violet/Brown
wire). If voltage is 1.8-2.6 volts, go to next step. If voltage is not
1.8-2.6 volts, repair open in Violet/Brown wire.

6) Using DRB in voltmeter mode, check voltage at ACM
connector terminal No. 22 (White/Black wire). If voltage is 1.8-2.6
volts, replace ACM. If voltage is not 1.8-2.6 volts, repair open in
White/Black wire.
OPEN FUSED IGNITION SWITCH OUTPUT (RUN/START) CKT
NOTE: Perform COMPONENT VERIFICATION TEST under DIAGNOSTIC TESTS
after all repairs. 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. Due to manufacturer changes in
wire colors, use terminal identification whenever possible.
1) Turn ignition on (engine off). Using DRB in voltmeter
mode, probe output side (Dark Blue wire) of fuse No. 19 located in
junction block. If voltage is less than 10 volts, repair open in Dark
Blue wire. If voltage is more than 10 volts, go to next step.
2) Turn ignition off and wait 2 minutes before proceeding.
Using DRB in ohmmeter mode, probe fused side (Light Green/Yellow wire)\
of fuse No. 19 located in junction block. If resistance is less than 5
ohms, go to next step. If resistance is more than 5 ohms, go to step
4).
3) Disconnect ACM connector. Using DRB in ohmmeter mode,
probe fused side (Light Green/Yellow wire) of fuse No. 19 located in
junction block. If resistance is less than 5 ohms, repair short to
ground in Light Green/Yellow wire an replace fuse No. 19. If
resistance is more than 5 ohms, replace ACM and fuse No. 19.
4) Turn ignition off and wait 2 minutes before proceeding.
Disconnect ACM. Using an ohmmeter, check resistance between ACM
connector terminal No. 14 (Light Green/Yellow wire) and fused side
(Light Green/Yellow wire) of fuse No. 19 located in junction block. If\
resistance is more than 5 ohms, repair open in Light Green/Yellow wire
and replace fuse No. 19. If resistance is less than 5 ohms, go to next
step.
5) Reconnect ACM connector. Turn ignition on (engine off).
replace fuse No. 19. Perform appropriate diagnostic test under
DIAGNOSTIC TESTS.
NO RESPONSE FROM POWERTRAIN CONTROL MODULE
NOTE: Perform COMPONENT VERIFICATION TEST under DIAGNOSTIC TESTS
after all repairs. 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. Due to manufacturer changes in
wire colors, use terminal identification whenever possible.
1) If engine does not run, repair as required. If engine
runs, disconnect Powertrain Control Module (PCM) connectors. Connect a\
jumper wire between ground and PCM Gray connector terminal C30
(Violet/Brown wire). Using DRB, perform CCD bus test. If DRB does not
display SHORT TO GROUND, repair open Violet/Brown wire. If DRB
displays SHORT TO GROUND, go to next step.
2) Connect a jumper wire between ground and PCM Gray
connector terminal C28 (White/Black wire). Using DRB, perform CCD bus
test. If DRB does not display SHORT TO GROUND, repair open White/Black
wire. If DRB displays SHORT TO GROUND, replace PCM.
REPAIRING SHORT TO BATTERY
NOTE: Perform COMPONENT VERIFICATION TEST under DIAGNOSTIC TESTS
after all repairs. Each time a connector is disconnected,