DODGE RAM 1999 Service Repair Manual

Fig. 3: Quad Driver Test (General Motors)
Courtesy of General Motors Corp.


N - R EM OVE/IN STA LL/O VER HAU L - D IE SEL

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Removal, Overhaul & Installation - Trucks - Diesel
Ram Pickup
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.
INTRODUCTION
Removal, overhaul and installation procedures are covered in
this article. If component removal and installation is primarily an
unbolt and bolt-on procedure, only a torque specification may be
furnished.
COMPUTERIZED ENGINE CONTROLS
POWERTRAIN CONTROL MODULE (PCM)
Removal & Installation
1) Disconnect negative battery cables. Disconnect electrical
connectors from PCM. The PCM is located at passenger's side rear
corner of engine compartment, on the firewall. See Fig. 1. Remove
mounting bolts and PCM.
2) To install, reverse removal procedure. Tighten mounting
bolts to specification. See TORQUE SPECIFICATIONS.
Fig. 1: Locating Powertrain Control Module (PCM)
Courtesy of Chrysler Corp.
AIR INDUCTION SYSTEMS

INTERCOOLER
NOTE: Intercooler may also be referred to as charge air cooler.
CAUTION: If vehicle had a turbocharger failure, or for any reason oil
was discharged into the intercooler, intercooler must be
removed and cleaned.
Removal
1) Remove front bumper. Remove front support bracket located
above center of intercooler. On A/C-equipped models, discharge A/C
system using approved refrigerant recovery/recycling equipment.
2) Disconnect and plug hoses and openings at condenser.
Remove condenser-to-intercooler screws and nuts. Remove condenser from
front of intercooler. Plug all openings on condenser.
3) On all models, remove intercooler inlet and outlet ducts.
See Fig. 2 . Remove intercooler bolts. Pivot intercooler forward and
upward to remove.
Inspection & Cleaning
1) Inspect intercooler for damaged fins or cracks. Replace
intercooler if damaged.
CAUTION: DO NOT use caustic cleaners to clean intercooler, or
intercooler may be damaged.
2) If intercooler cleaning is required, flush intercooler
with a non-caustic solvent in the opposite direction of normal
airflow. Use soft-faced hammer to lightly tap on end tanks on
intercooler to dislodge any trapped material.
3) Continue flushing intercooler until all material is
removed from intercooler. Use light to inspect inside of intercooler
for remaining material.
4) Once intercooler is clean, wash intercooler with soap and
hot water to remove remaining solvent. Once remaining solvent is
removed, use clean water to rinse intercooler. Blow compressed air
into intercooler in the opposite direction of the normal airflow until
intercooler is dry.
Installation
To install, reverse removal procedure. Tighten fasteners to
specification. See TORQUE SPECIFICATIONS. On A/C-equipped models,
evacuate and charge A/C system.
Fig. 2: Exploded View Of Intercooler & Components
Courtesy of Chrysler Corp.
TURBOCHARGER

CAUTION: If turbocharger failure exists, intercooler must be cleaned.
See INTERCOOLER under AIR INDUCTION SYSTEMS.
Removal
1) Disconnect negative battery cables. Disconnect air inlet
tube and exhaust pipe from turbocharger. Disconnect intercooler inlet
duct from turbocharger. See Fig. 2.
2) Disconnect and plug turbocharger oil supply line and
turbocharger oil drain line at turbocharger. Remove turbocharger
retaining nuts, turbocharger and gasket from exhaust manifold. Plug
all air intake openings.
Installation
1) Apply anti-seize compound on turbocharger mounting studs.
Using NEW gasket, install turbocharger. Install and tighten
turbocharger retaining nuts to specification. See TORQUE
SPECIFICATIONS.
2) Using NEW gasket, install turbocharger oil drain line on
turbocharger. Install and tighten turbocharger oil drain line bolts to
specification. See TORQUE SPECIFICATIONS.
CAUTION: Turbocharger must be pre-lubricated by pouring clean engine
oil in turbocharger oil supply line fitting on turbocharger
before starting the engine.
WARNING: DO NOT rotate turbine wheel in turbocharger with your finger,
as sharp edges may exist.
3) Pour 3 ozs. (60 cc) of clean engine oil into turbocharger\
oil supply line fitting on turbocharger while using soft object to
rotate turbine wheel in turbocharger. This must be done to pre-
lubricate the turbocharger.
4) Install turbocharger oil supply line on turbocharger and
tighten nut to specification. See TORQUE SPECIFICATIONS. To install
remaining components, reverse removal procedure. Tighten bolts/nuts to
specification. See TORQUE SPECIFICATIONS.
TURBOCHARGER WASTEGATE ADJUSTMENT
NOTE: For turbocharger wastegate adjustment, see CONTROL ROD
ADJUSTMENT under TURBOCHARGER WASTEGATE in ON-VEHICLE
ADJUSTMENTS - DIESEL article.
ENGINE SENSORS & SWITCHES
ENGINE COOLANT TEMPERATURE SENSOR
Removal & Installation
1) Engine coolant temperature sensor is located at front of
cylinder head near thermostat. See Fig. 3.
2) Partially drain cooling system until coolant level is
below the cylinder head. Disconnect ECT sensor electrical connector.
Remove ECT sensor from cylinder head. Discard "O" ring. To install,
reverse removal procedure. Use new "O" ring.
CRANKSHAFT POSITION SENSOR (CKP)
NOTE: Crankshaft Position (CKP) sensor may be referred to as engine\
speed sensor.
Removal & Installation
1) CKP sensor is located on left rear side of engine block

near starter motor. See Fig. 3. Disconnect negative battery cables.
Disconnect electrical wiring harness connector for CKP sensor.
2) Remove starter motor. Remove CKP sensor mounting bolt and
bracket. Pull CKP sensor from engine block with a twisting motion. To
install CKP sensor, reverse removal procedure. Tighten CKP bolt to
specification. See TORQUE SPECIFICATIONS
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
Removal & Installation
1) Disconnect electrical connector from intake manifold air
temperature sensor. See Fig. 3. Remove intake manifold air temperature
sensor from intake manifold cover.
2) To install, reverse removal procedure. Tighten intake
manifold air temperature sensor to specification. See TORQUE
SPECIFICATIONS.
Fig. 3: Locating Diesel System Components
Courtesy of Chrysler Corp.
PARK/NEUTRAL SWITCH

Removal (A/T Models)
Raise and support vehicle. Disconnect electrical connector
from park/neutral switch. Park/neutral switch is located on side of
transmission case, near shift linkage. Unscrew park/neutral switch
from transmission case. Remove seal ring from park/neutral switch.
Installation
1) Apply parking brake. Place shift lever in Park and
Neutral. Ensure park/neutral switch operating levers in transmission
are centered in the park/neutral switch opening on transmission case.
2) Using NEW seal ring, install park/neutral switch. Tighten
park/neutral switch to specification. See TORQUE SPECIFICATIONS.
Install electrical connector. Add ATF as necessary.
ACCELERATOR PEDAL POSITION SENSOR (APPS)
NOTE: APPS is replaced as assembly, including lever, brackets, and
sensor.
Removal
1) Disconnect negative battery cables. Remove cable cover.
Using finger pressure only, disconnect end of speed control servo
cable from throttle lever pin by pulling forward on connector while
holding lever rearward. Using 2 small screwdrivers, pry throttle cable
connector socket from throttle lever ball.
2) Disconnect transmission kickdown cable (if equipped).
Compress pinch tabs on cruise control and throttle cables. Pull cables
rearward to remove from cable mounting brackets. See Fig. 4.
Disconnect electrical connector and retaining bolts. Remove APPS
sensor.
Installation
To install, reverse removal procedure. To calibrate ECM, turn
ignition on. Without starting engine, slowly press throttle pedal to
floor and then slowly release.
Fig. 4: Locating Throttle Position (TP) Sensor
Courtesy of Chrysler Corp.
RELAYS & SOLENOIDS

FUEL HEATER RELAY
Removal & Installation
Fuel heater relay is located in Power Distribution Center
(PDC). Check label under PDC cover for relay location. To install,
reverse removal procedure.
INTAKE MANIFOLD AIR HEATER RELAYS
Removal & Installation
1) Intake manifold air heater relays are mounted on inner
wheelwell, below driver's side battery. See Fig. 5. Disconnect
negative battery cables.
2) Note location of wiring on intake manifold air heater
relays for installation reference. Disconnect electrical connectors at
intake manifold air heater relays.
3) Remove retaining bolts and intake manifold air heater
relay assembly. Both relays and mounting bracket are replaced as an
assembly. To install, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS.
Fig. 5: Locating Intake Manifold Air Heater Relays
Courtesy of Chrysler Corp.
FUEL SYSTEM

FUEL LINE DISCONNECT FITTINGS
NOTE: Fuel lines may contain single tab, dual tab or plastic
retainer ring disconnect fitting. See Fig. 6. Determine type
of disconnect fitting used and use proper procedure for
proper disconnect fitting.
Fig. 6: Identifying Fuel Line Disconnect Fitting
Courtesy of Chrysler Corp.
Removal & Installation (Single Tab)
1) Disconnect negative battery cables. Ensure disconnect

fitting and fuel lines are clean. Note location of release tab and
pull tab on disconnect fitting. See Fig. 6.
CAUTION: Release tab must be pressed downward before removing pull tab
or pull tab will be damaged.
2) Press release tab downward. Use screwdriver to pry pull
tab upward until pull tab separates from disconnect fitting. Remove
disconnect fitting from fuel line. Inspect components for damage. If
disconnect fitting is damaged, entire assembly must be replaced, as
only pull tab can be replaced.
3) To install, ensure fuel line and disconnect fitting are
clean. Lubricate fuel line and disconnect fitting with engine oil.
Install disconnect fitting on fuel line until disconnect fitting
bottoms on fuel line.
4) Install NEW pull tab until pull tab locks in disconnect
fitting. DO NOT reuse old pull tab. Pull on fuel line and disconnect
fitting to ensure components are properly locked together. Reconnect
negative battery cables. Start engine and check for leaks.
Removal & Installation (Dual Tab)
1) Disconnect negative battery cables. Ensure disconnect
fitting and fuel lines are clean. Note location of tabs on disconnect
fitting. See Fig. 6.
2) Squeeze both tabs against disconnect fitting. Pull
disconnect fitting from fuel line. The plastic retainer will remain on
the fuel system component being serviced. The "O" rings and spacer
will remain in the disconnect fitting.
3) Inspect components for damage. If disconnect fitting is
damaged, entire assembly must be replaced. The only component that may
be replaced is the plastic retainer. If plastic retainer must be
removed from fuel system component, carefully release the plastic
retainer from the fuel system component using 2 screwdrivers. Inspect
plastic retainer for cracks or damage. Replace plastic retainer if
defective.
4) To install, ensure fuel line and disconnect fitting are
clean. Lubricate fuel line and disconnect fitting with engine oil.
Install disconnect fitting on fuel line until click sound is heard.
5) Pull on fuel line and disconnect fitting to ensure
components are properly locked together. Reconnect negative battery
cables. Start engine and check for leaks.
Removal & Installation (Plastic Retainer Ring)
1) Disconnect negative battery cables. Ensure disconnect
fitting and fuel lines are clean. Note location of plastic retainer
ring on disconnect fitting. See Fig. 6.
NOTE: Plastic retainer ring must be pressed evenly into disconnect
fitting. If plastic retainer is not even, it will be
difficult to remove disconnect fitting from fuel line.
2) Firmly push disconnect fitting toward the fuel line while
pushing plastic retainer ring evenly into disconnect fitting. With
plastic retainer ring fully depressed, pull disconnect fitting from
fuel line.
3) Inspect components for damage. If disconnect fitting is
damaged, entire assembly must be replaced.
4) To install, ensure fuel line and disconnect fitting are
clean. Lubricate fuel line and disconnect fitting with engine oil.
Install disconnect fitting on fuel line until click sound is heard.
5) Pull on fuel line and disconnect fitting to ensure
components are properly locked together. Reconnect negative battery
cables. Start engine and check for leaks.

FUEL LINE BLEEDING
NOTE: Fuel line bleeding is necessary if fuel injection pump is
replaced, fuel filter/water separator is not filled with
diesel fuel before installing or vehicle ran out off fuel.
Bleed high-pressure fuel lines if connections are loosened or
replaced. If engine has not been operated for an extended
time, bleed fuel lines before next initial engine start-up.
WARNING: DO NOT bleed fuel lines on a hot engine, as high exhaust
temperatures may cause a fire. Carefully bleed fuel lines, as
fuel is under extremely high pressure and could penetrate
skin. Use safety goggles and protective clothing when
bleeding fuel lines.
1) Loosen banjo bolt holding low-pressure fuel supply line to
side of fuel injection pump. Wrap a towel around banjo fitting to
catch fuel. Crank engine quickly and release key before engine starts.
This will operate fuel transfer pump for about 25 seconds.
2) If fuel is not present at fuel supply line after 25
seconds, turn ignition off. Repeat engine crank procedure until fuel
is present at fuel supply line. Tighten banjo bolt at fuel supply line
to specification. See TORQUE SPECIFICATIONS.
CAUTION: Ensure parking brake is applied and transmission is in
Neutral before bleeding fuel injection pump or high-pressure
fuel lines. DO NOT operate starter for more than 30 seconds
when bleeding fuel injection pump or high-pressure fuel
lines. Allow 2-minute intervals between starter operations.
3) To bleed air from fuel injection pump, ensure parking
brake is applied and transmission is in Neutral, as engine may start
when operating starter to bleed air from fuel injection pump. Operate
starter for 30 seconds to bleed any trapped air in fuel injection
pump.
4) To bleed high-pressure fuel lines, ensure parking brake is
applied and transmission is in Neutral, as engine may start when
operating starter to bleed high-pressure fuel lines. Loosen high-
pressure fuel line nut at fuel injector.
5) Operate starter until steady fuel flow exists at high-
pressure fuel line. Tighten high-pressure fuel line nut to
specification. See TORQUE SPECIFICATIONS. Start engine. Repeat
procedure on each high-pressure fuel line until engine operates
smoothly.
FUEL FILTER/WATER SEPARATOR & WATER-IN-FUEL SENSOR
NOTE: Vehicle also contains an in-tank fuel filter located on
bottom of fuel tank module. For servicing procedure, see FUEL
TANK MODULE & IN-TANK FUEL FILTER under FUEL SYSTEM.
NOTE: When fuel filter/water separator is being replaced,
manufacturer recommends cleaning the pre-filter. See FUEL
HEATER under FUEL SYSTEM for servicing of pre-filter.
Removal
1) Ensure engine is off. Place drain pan below drain tube at
fuel filter/water separator. See Fig. 3. Rotate handle on drain valve
forward, toward front of vehicle to DRAIN position. Drain valve is
located near top of fuel filter/water separator. See Fig. 3. Once fuel
is drained from fuel filter/water separator, rotate handle on drain
valve back to CLOSE position.