engine DODGE RAM 1999 Service Repair Manual
Page 1189 of 1691
Ram Pickup, Ram Van & Ram Wagon ........... (2) .............. ( 2)
Town & Country
3.3L & 3.8L ............................. ( 2) .............. ( 2)
Voyager
2.4L
A/C & Generator ...................... 190 (86) ...... 115 (52\
)
Power Steering ....................... 140 (64) ....... 90 (41\
)
3.0L
A/C .................................. 150 (68) ....... 80 (36\
)
Generator & Power Steering ............. ( 2) .............. ( 2)
3.3L .................................... ( 2) .............. ( 2)
( 1) - Used belt is a belt that has been in service for more than 15
minutes.
( 2) - Automatic belt tensioner is used. Belt tension adjustment is not
required.
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MECHANICAL CHECKS
ENGINE COMPRESSION
Ensure battery is fully charged. Warm engine to normal
operating temperature. Disconnect wire at ignition coil to prevent
engine from starting. Check engine compression with all spark plugs
removed and throttle wide open.
COMPRESSION SPECIFICATIONS
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Application Specification
Compression Ratio
Caravan
2.4L ...................................................... 9.4:1
3.0L ...................................................... 8.9:1
3.3L ...................................................... 8.9:1
3.8L ...................................................... 9.6:1
Dakota & Durango ........................................... 9.1:1
Ram Pickup
3.9L, 5.2L & 5.9L (Gasoline) .............................. 9.1:1\
5.9L (Diesel) ............................................ 17.5:1\
8.0L ...................................................... 8.4:1
Ram Van & Ram Wagon ........................................ 9.1:1
Town & Country
3.3L ...................................................... 8.9:1
3.8L ...................................................... 9.6:1
Voyager
2.4L ...................................................... 9.4:1
3.0L ...................................................... 8.9:1
3.3L ...................................................... 8.9:1
Normal Compression Pressure
Caravan
2.4L ............................. 170-225 psi (11.9-15.7 kg/cm
)
3.0L ...................................... 178 psi (12.5 kg/cm)
3.3L & 3.8L ................................................. ( 1)
Dakota
2.5L .............................. 120-150 psi (8.4-10.5 kg/cm
)
3.9L, 5.2L & 5.9L ........................................... ( 1)
Durango ...................................................... ( 1)
Ram Pickup, Ram Van & Ram Wagon .............................. ( 1)
Town & Country ............................................... ( 1)
Voyager
Page 1190 of 1691
2.4L ............................. 170-225 psi (11.9-15.7 kg/cm)
3.0L ...................................... 178 psi (12.5 kg/cm)
3.3L ........................................................ ( 1)
Minimum Compression Pressure
Caravan, Town & Country, & Voyager .......... 100 psi (7.0 kg/cm
)
Dakota
2.5L ........................................................ ( 1)
3.9L, 5.2L & 5.9L .......................... 100 psi (7.0 kg/cm
)
Durango ..................................... 100 psi (7.0 kg/cm)
Ram Pickup
3.9L, 5.2L & 5.9L (Gasoline) & 8.0L ........ 100 psi (7.0 kg/cm
)
5.9L (Diesel) ............................................... ( 1)
Ram Van & Ram Wagon ......................... 100 psi (7.0 kg/cm
)
Maximum Variation Between Cylinders
Caravan, Town & Country & Voyager ..................... 25 Percent
Dakota
2.5L ........................................ 30 psi (2.1 kg/cm
)
3.9L, 5.2L & 5.9L ........................................... ( 1)
Durango ...................................................... ( 1)
Ram Pickup, Ram Van & Ram Wagon .............................. ( 1)
( 1) - Information is not available from manufacturer.
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VALVE CLEARANCE
Gasoline Models
All engines are equipped with hydraulic lifters. No
adjustments are required.
5.9L Diesel (Ram Pickup)
Valve adjustment is recommended every 150 months or 150,000
miles during normal service, every 135,000 miles during severe
service. Severe service is described as frequent short trip operation
of less than 5 miles, long periods of engine idling, trailer towing,
police, taxi, local delivery service, or operating in dusty or
excessively hot conditions. See VALVE CLEARANCE SPECIFICATIONS
(DIESEL) table.
VALVE CLEARANCE SPECIFICATIONS (DIESEL) ( 1)
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Application In. (mm)\
Intake Valve ............................................ .010 (.25)\
Exhaust Valve ........................................... .020 (.51)\
(1) - Adjust valves with engine temperature less than 140
F (60C). \
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IGNITION SYSTEM
IGNITION COIL
IGNITION COIL RESISTANCE - Ohms @ 70-80F (21-27C) \
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Application Primary Secondary
Caravan
2.4L
Diamond ( 1)( 2) ............... .53-.65 .......... 11,500-13,500
Weastec ( 1) .................. .45-.65 .......... 10,900-14,700
3.0L ............................. ( 3) ..................... ( 3)
Page 1199 of 1691
Caravan
2.4L & 3.0L ............ (2) 43-53 (3.0-3.7) ............... ( 3)
3.3L
Flex-Fuel ............. ( 2) 50-60 (3.5-4.2) ............... ( 3)
Except Flex-Fuel ...... ( 2) 43-53 (3.0-3.7) ............... ( 3)
3.8L ................... ( 2) 43-53 (3.0-3.7) ............... ( 3)
Dakota & Durango ......... ( 1) 44-54 (3.0-3.8) ........... .5 (24)
Ram Pickup, Ram Van
& Ram Wagon ............. ( 1) 44-54 (3.0-3.8) ........... .5 (24)
Town & Country
3.3L
Flex-Fuel ............. ( 2) 50-60 (3.5-4.2) ............... ( 3)
Except Flex-Fuel ...... ( 2) 43-53 (3.0-3.7) ............... ( 3)
3.8L ................... ( 2) 43-53 (3.0-3.7) ............... ( 3)
Voyager
2.4L & 3.0L ............ ( 2) 43-53 (3.0-3.7) ............... ( 3)
3.3L
Flex-Fuel ............. ( 2) 50-60 (3.5-4.2) ............... ( 3)
Except Flex-Fuel ...... ( 2) 43-53 (3.0-3.7) ............... ( 3)
( 1) - Manufacturer lists fuel pressure with engine idling.
( 2) - Manufacturer lists fuel pressure with engine off, ignition on
and using scan tool to activate fuel pump.
( 3) - Information is not available from manufacturer.
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FUEL INJECTION PUMP & FUEL TRANSFER PUMP (DIESEL)
NOTE: For fuel injection pump timing, see appropriate ON-VEHICLE
ADJUSTMENTS article.
FUEL INJECTION PUMP PERFORMANCE (DIESEL)
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Application Output Pressure psi (kg/cm)
Ram Pickup 5.9L ................................................ ( 1)
( 1) - Pressure testing procedure and output pressure is not available
from manufacturer.
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NOTE: For testing of fuel transfer pump, see appropriate BASIC
DIAGNOSTIC PROCEDURES article.
INJECTOR OPENING PRESSURE (DIESEL)
INJECTOR OPENING PRESSURE (DIESEL) \
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Application psi (kg/cm)
Ram Pickup 5.9L ......................................... 4500 (316)\
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INJECTOR RESISTANCE
INJECTOR RESISTANCE \
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Application Ohms @ 68F (20C)
All Models ................................................... 10-16
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Page 1210 of 1691
ON-VEHICLE TESTING
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 article in GENERAL INFORMATION
before disconnecting battery.
DISABLING/ENABLING IGNITION & FUEL SYSTEMS
WARNING: To prevent engine from starting while performing tests,
always disable ignition and fuel systems.
Disabling Ignition & Fuel Systems
Remove Automatic Shutdown Relay (ASD) located in Power
Distribution Center (PDC). Refer to PDC cover for proper relay
location. PDC is located in engine compartment. On 5.9L diesel
engines, also disconnect fuel shutdown solenoid connector. Solenoid is
located behind upper intake manifold. See appropriate SYSTEM &
COMPONENT TESTING article in ENGINE PERFORMANCE section.
Enabling Ignition & Fuel Systems
When testing and/or repairs have been completed, verify
battery condition. Recharge battery as necessary, after starter tests
have been completed. Disconnect all test equipment. Install ASD relay.
On 5.9L diesel engines, reconnect fuel shutdown relay connector. On
all models, start engine several times to verify malfunction has been
corrected.
CRANKING TEST
NOTE: Ensure engine is at normal operating temperature. High
viscosity oil, extreme cold temperatures, or tight engine
will increase amperage draw.
1) Using a battery load tester, connect positive and negative
leads to battery. Connect inductive ammeter pick-up to positive
battery cable. Disable ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS.
2) Ensure all lights and accessories are off. Place A/T in
Park position or M/T in Neutral position. Apply parking brake. Crank
engine and observe voltmeter reading. If voltage is more than 9.6
volts and cranking amperage draw is more than specified amps, proceed
to CIRCUIT RESISTANCE TESTS. See STARTER SPECIFICATIONS - CARS or
STARTER SPECIFICATIONS - TRUCKS.
3) If voltage is 12.5 volts or more and cranking amperage
draw is less than specified, check starter circuit components in the
following order:
starter solenoid, starter relay, starter relay circuit, park/neutral
position switch or transmission range sensor (A/T), clutch pedal
position switch (M/T), ignition switch, wiring harness and
connections.
CIRCUIT RESISTANCE TESTS
NOTE: If excessive resistance is not found in circuits being
tested, remove starter and proceed to BENCH TESTING.
Battery Connection Resistance Test
1) Disable vehicle ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS. A voltmeter accurate to
one tenth of a volt will be needed for the following tests.
Page 1211 of 1691
2) Connect voltmeter positive lead to negative battery cable
clamp. Connect voltmeter negative lead to negative battery post. Crank
engine and observe voltmeter reading. If voltage is detected, repair
poor contact between cable clamp and post. Perform same procedure to
positive battery post and cable clamp.
Ground Connection Resistance Test
Connect voltmeter negative lead to negative battery post.
Connect voltmeter positive lead to engine block, near negative battery
cable grounding point. Crank engine and observe voltmeter reading. If
voltmeter reading indicates more than 0.2 volt, repair poor ground
connection or replace ground cable.
Starter Ground Connection Resistance Test
Connect voltmeter negative lead to negative battery post.
Connect voltmeter positive lead to starter housing. Crank engine and
observe voltmeter reading. If voltmeter reading indicates more than 0.
2 volt, repair poor starter-to-ground connection.
Positive Battery Cable Resistance Test
1) Remove starter heat shield (if equipped) to gain access t\
o
starter solenoid connections. Connect voltmeter negative lead to
starter solenoid battery terminal and voltmeter positive lead to
positive battery post.
2) Crank engine and observe voltmeter reading. If voltage
reads more than 0.2 volt, correct poor connection between battery
cable and starter solenoid or replace positive battery cable.
SOLENOID CIRCUIT TEST
NOTE: Perform SOLENOID CIRCUIT TEST before testing starter relay
and starter relay circuit. Ensure A/T is in Park position or
M/T is in Neutral position and parking brake is applied.
1) Disable vehicle ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS.
2) Ensure battery is fully charged. Ensure solenoid
connections are not loose or corroded. Remove starter relay from Power
Distribution Center (PDC). Refer to PDC cover for proper relay
location. PDC is located in engine compartment.
3) Connect a remote starter switch or jumper wire between
starter relay socket terminal No. 87 and positive battery post. See
Fig. 1 or 2. If engine cranks, solenoid and starter are good. Go to
STARTER RELAY TEST.
4) If engine fails to crank, or if solenoid chatters, check
wiring and connectors from starter relay socket to starter solenoid
terminal. Repair any loose or corroded connections. If engine still
fails to crank, remove starter and proceed to SOLENOID TEST under
BENCH TESTING.
STARTER RELAY TEST
NOTE: Perform SOLENOID CIRCUIT TEST before testing starter relay.
Remove starter relay from Power Distribution Center (PDC).
Refer to PDC cover for proper relay location. PDC is located in engine
compartment. Connect 12-volt power source to starter relay terminal
No. 86 and ground terminal No. 85. See Fig. 1 or 2. Using ohmmeter,
check continuity across starter relay terminals No. 30 and 87. If
continuity is not present, replace starter relay.
Page 1214 of 1691
STARTER RELAY CIRCUIT TEST
NOTE: Perform STARTER RELAY TEST before testing starter relay
circuit.
1) Ensure battery is fully charged. Remove starter relay from
Power Distribution Center (PDC). Refer to PDC cover for proper relay
location. PDC is located in engine compartment.
2) Connect a jumper wire between starter relay socket
terminal No. 30 and terminal No. 87. See Fig. 1 or 2. If engine does
not crank, go to SOLENOID TEST under BENCH TESTING. If engine cranks,
go to next step.
3) Turn ignition on. Check voltage between ground and starter
relay socket terminal No. 30. If battery voltage is not present,
repair open in circuit between starter relay socket and battery. If
battery voltage is present, go to next step.
4) Check voltage between ground and starter relay socket
terminal No. 86 with ignition switch in START position and clutch
pedal depressed (if equipped with M/T). If battery voltage is present,\
circuit is okay. Go to step 6) if equipped with M/T or step 7) if
equipped with A/T. If battery voltage is not present, repair open in
circuit between ignition switch and starter relay socket (A/T) or go
to next step (M/T).
5) Unplug wiring connector from clutch position switch
mounted on clutch pedal bracket. Connect jumper wire between clutch
position switch connector terminals. Recheck for voltage at starter
relay socket terminal No. 86 with ignition switch in START position.
If battery voltage is present, check clutch position switch adjustment
(if applicable). Adjust switch as necessary. If switch adjustment is
okay, check clutch position switch. See CLUTCH POSITION SWITCH TEST.
If battery voltage is not present, repair wiring between ignition
switch and starter relay socket as necessary.
6) On M/T models, connect voltmeter negative lead to starter
relay socket terminal No. 85 and positive lead to terminal No. 86.
Turn ignition switch to START position and depress clutch pedal. If
battery voltage is present, starter relay socket ground circuit is
good. Replace faulty starter relay. If battery voltage is not present,
repair ground wire circuit.
7) On A/T models, connect voltmeter negative lead to starter
relay socket terminal No. 85 and positive lead to terminal No. 86.
Ensure transmission gear selector is in Park or Neutral position.
Ground circuit runs through Park/Neutral Position (PNP) switch or
Transmission Range (TR) sensor on transmission. Turn ignition switch
to START position. If battery voltage is present, starter relay socket
ground circuit is good. Replace faulty starter relay.
8) If battery voltage is not present, check PNP switch or TR
sensor for loose or damaged connections. Also, check ground to PNP
switch or TR sensor. Repair as necessary. If connections and ground
are okay, check PNP switch or TR sensor. See PARK/NEUTRAL POSITION
(PNP) SWITCH & TRANSMISSION RANGE (TR) SENSOR TEST.
PARK/NEUTRAL POSITION (PNP) SWITCH & TRANSMISSION RANGE (TR)
SENSOR TEST
NOTE: Transmission Range (TR) sensor may be also known as
Park/Neutral Position (PNP) switch or Park/Neutral switch.
NOTE: The following test is for Caravan, Ram Van, Ram Wagon and
Voyager with 3-speed transmission. All other models are
equipped with a Transmission Range (TR) sensor. If TR sensor
or sensor circuit is defective, see appropriate NTC test in
appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE
section.
Page 1216 of 1691
Bosch 2.0L .................................................. (2)
Melco 2.5L & 2.7L ........................................... ( 2)
Nippondenso 2.4L, 2.7L & 3.5L ............................... ( 2)
Power Rating
Bosch 2.0L ............................................... 0.95 Kw
Melco 2.5L & 2.7L ......................................... 1.2 Kw
Nippondenso 2.4L, 2.7L & 3.5L ............................... 1.4 Kw
( 1) - With engine at normal operating temperature. High viscosity oil,
extreme cold temperatures, or tight engine will increase
amperage draw.
( 2) - Information is not available from manufacturer.
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STARTER SPECIFICATIONS - TRUCKS \
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Application Specification
Cranking Amperage Draw ( 1)
Caravan, Town & Country & Voyager ................... 150-200 Amps
Dakota & Durango
2.5L ................................................... 130 Amps
3.9L, 5.2L & 5.9L .................................. 125-250 Amps
Ram Pickup
Diesel Engines ..................................... 450-700 Amps
Gasoline Engines ................................... 125-250 Amps
Ram Van & Ram Wagon ................................. 125-250 Amps
No-Load Test At 11 Volts
Maximum Amps
Caravan, Town & Country & Voyager ....................... 73 Amps
Dakota & Durango
2.5L .................................................. 90 Amps
3.9L, 5.2L & 5.9L ..................................... 73 Amps
Ram Pickup
Gasoline .............................................. 73 Amps
Diesel ............................................... 200 Amps
Ram Van & Ram Wagon ..................................... 73 Amps
Minimum RPM
Caravan, Town & Country & Voyager ...................... 3401 RPM
Dakota & Durango
2.5L ................................................. 2600 RPM
3.9L, 5.2L & 5.9L .................................... 3601 RPM
Ram Pickup
Gasoline ............................................. 3601 RPM
Diesel ............................................... 3000 RPM
Ram Van & Ram Wagon .................................... 3601 RPM
Power Rating
Caravan, Town & Country & Voyager ......................... 1.2 Kw
Dakota & Durango
2.5L ..................................................... 1.2 Kw
3.9L, 5.2L & 5.9L ........................................ 1.4 Kw
Ram Pickup
Gasoline ................................................. 1.4 Kw
Diesel ................................................... 2.7 Kw
Ram Van & Ram Wagon ....................................... 1.4 Kw
( 1) - With engine at normal operating temperature. High viscosity oil,
extreme cold temperatures, or tight engine will increase
amperage draw.
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TORQUE SPECIFICATIONS
Page 1217 of 1691
TORQUE SPECIFICATIONS - CARS & TRUCKS \
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Application Ft. Lbs. (N.m)\
Starter Mounting Bolts & Nuts
All Except Dakota, Durango,
Ram Pickup, Ram Van & Ram Wagon ......................... 40 (54)\
Dakota & Durango
2.5L .................................................... 33 (45)\
3.9L, 5.2L & 5.9L ....................................... 50 (68)\
Ram Pickup
Diesel Engines .......................................... 32 (43)\
Gasoline Engines ........................................ 50 (68)\
Ram Van & Ram Wagon ...................................... 50 (68)\
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WIRING DIAGRAMS
Page 1230 of 1691
STE ER IN G C O LU M N S W IT C HES
1999 D odge P ic ku p R 1500
1999 ACCESSORIES & EQUIPMENT
CHRY - Steering Column Switches
Dakota, Durango & Ram Pickup
WARNING: Deactivate air bag system before performing any service
operation involving steering column components. See
appropriate AIR BAG RESTRAINT SYSTEMS article. DO NOT apply
electrical power to any component on steering column without
first disconnecting air bag module. Air bag may deploy. Wait
at least 2 minutes after disconnecting negative battery cable
before servicing air bag system. System reserve capacitor,
integral to ACM, maintains air bag system voltage for about 2
minutes after battery is disconnected. Servicing air bag
system before 2-minute period may cause accidental air bag
deployment and possible personal injury.
DESCRIPTION
Turn signal, hazard flasher, headlight beam selector,
headlight flash-to-pass, windshield wipe, pulse wipe and windshield
wash systems use a common switch assembly (multifunction switch)
mounted within upper steering column housing.
Ignition switch and lock cylinder are incorporated into an
assembly attached to side of steering column. Ignition switch assembly
can be serviced as a separate unit, but requires removal of lock
cylinder.
COMPONENT LOCATIONS
COMPONENT LOCATIONS \
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Component Location
Combination Flasher Relay ........................... Junction Block
Horn ............................... In Right Front Corner Of Engine
Compartment
Horn Relay ............................ In Power Distribution Center
Junction Block ................. Under Left Side Of Instrument Panel
Power Distribution Center ...... In Left Side Of Engine Compartment,
On Left Inner Panel
Relay/Flasher Module ........ Under Right Side Of Instrument Panel,
Behind Glove Box
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TROUBLE SHOOTING
TURN SIGNAL AND HAZARD FLASHER SYSTEM
Bulbs Burn Out Rapidly
Check charging system. See appropriate GENERATORS &
REGULATORS article in STARTING & CHARGING SYSTEMS.
Hazard Flashers Inoperative
Blown fuse. Faulty hazard flasher. Open circuit in feed wire
to hazard switch. Faulty turn signal/hazard switch. Open or grounded
circuit in wiring to external lights.
Page 1247 of 1691
NOTE: Before testing, check fluid level, belt tension, pump pulley,
tire pressure and engine idle speed.
HYDRAULIC SYSTEM PRESSURE TEST
NOTE: Replacement fittings are required on Pressure Test Gauge(C
-3309E) for adapting to "O" ring type hose tube ends.
Idle Pressure Test
1) Remove high pressure hose at steering pump and connect a
spare hose to pump fitting. Connect opposite end of spare hose to
Pressure Test Gauge (C-3309E). Connect pressure hose from valve side
of steering gear to valve side of gauge. Valve must be installed on
outlet side of gauge. See Fig. 2.
2) Fully open shutoff valve on test gauge. With a thermometer
in fluid reservoir, start engine and warm fluid to 150-170
F (66-
77 C). Turning wheels from stop-to-stop will aid in warming fluid. DO
NOT hold wheels against stop.
3) With engine at idle and gauge valve open, check initial
pressure. See POWER STEERING PUMP PRESSURE TEST SPECIFICATIONS table.
If pressure is greater than 125 psi (8.8 kg/cm
), check for restricted
hoses or crimped lines.
Fig. 2: Installing Pressure Gauge
Courtesy of Chrysler Corp.
POWER STEERING PUMP PRESSURE TEST SPECIFICATIONS
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Application psi (kg/cmFD)
Idle Pressure ...................................... 50-80 (3.5-5.6)\
Relief Pressure
Dakota (4WD) ........................................ 1450 (101.9\
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Ram Pickup .......................................... 1450 (101.9)\
Ram Van/Wagon ........................................ 1400 (98.4)\
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CAUTION: DO NOT leave shutoff valve closed more than 5 seconds, or
pump damage could result.