compression ratio DODGE RAM 1999 Service Repair Manual
Page 75 of 1691
(such as compression
fitting) ............... B ............ Require replacement.
Flange leaking .......... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Restricted internally ... A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
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EXPANSION VALVES
EXPANSION VALVE INSPECTION \
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Condition Code Procedure
Application incorrect ... B ............ Require 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.
Corroded internally ..... 1 ............ Suggest replacement.
Filter screen torn ...... A .. Require replacement of screen.
Inoperative ............. A ........... ( 1) Require repair or
replacement.
Leaking ................. A ............ Require replacement.
Restricted .............. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Expansion valve operation may be affected by capillary
tube location, corrosion, and insulation tape.
Inoperative includes intermittent operation.
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FUNCTION SELECTORS
See CONTROL HEADS (FUNCTION SELECTORS) .
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSE, FUSIBLE LINK AND CIRCUIT BREAKER INSPECTION \
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Blown ................... A ........ ( 1) Require replacement.
Corroded, affecting
performance ............ A .. Require repair or replacement.
Corroded, not affecting
performance ............ 2 .. Suggest repair or replacement.
Cracked, affecting
performance ............ A .. Require repair or replacement.
Cracked, not affecting
performance ............ 1 .. Suggest repair or replacement.
Inoperative ............. A ... ( 2) Require replacement.
Insulation damaged,
Page 288 of 1691
13) On A/T models, ensure all electrical connectors are clean
and properly connected to electrical plugs on transmission case. On
all models, check for loose or defective electrical connections on
starter and starter solenoid.
MECHANICAL INSPECTION
Compression
Manufacturer does not provide information for checking
compression.
FUEL SYSTEM
AIR IN FUEL SYSTEM
NOTE: Air in the fuel system may cause hard starting, rough
running, excessive smoke, poor engine performance, engine
misfire, poor fuel economy and fuel knock. Air may enter fuel
system whenever fuel supply lines, fuel filter/water
separator, fuel injection pump, fuel injectors or high
-pressure fuel lines are removed or disconnected.
1) Inspect all low-pressure fuel lines from fuel tank to fuel
transfer pump, fuel heater and fuel filter/water separator for signs
of leakage. Inspect all high-pressure fuel lines for signs of leakage.
See FUEL INJECTOR & HIGH-PRESSURE FUEL LINES under FUEL SYSTEM.
2) After repairing fuel leak, bleed air from fuel system. See
FUEL LINE BLEEDING under FUEL SYSTEM in REMOVAL, OVERHAUL &
INSTALLATION - TRUCKS - DIESEL article.
FUEL HEATER
1) Fuel heater is located in fuel filter/water separator. See
Fig. 1 . Fuel heater uses a fuel heater temperature sensor for
controlling operation of the fuel heater.
2) A defective fuel heater may cause excessive wax build-up
in the fuel filter/water separator during cold ambient temperatures.
Wax build-up may cause hard starting, prevent engine from
accelerating, low power, Blue smoke or White smoke. For testing of
fuel heater and fuel heater temperature sensor, see SYSTEM & COMPONENT
TESTING - TRUCKS - DIESEL article.
FUEL HEATER RELAY
Ensure fuel heater relay, located in power distribution
center is installed correctly and that terminals are not corroded. For
fuel heater relay testing, see SYSTEM & COMPONENT TESTING - TRUCKS -
DIESEL article.
FUEL FILTER/WATER SEPARATOR
NOTE: A blocked or restricted fuel filter/water separator may cause
starting problems, prevent engine from accelerating, low
power or White smoke. If an excessive amount of water
collects in filter/separator in a short period of time, it
may be necessary to drain and clean fuel tank.
1) When ignition switch is first turned to ON position,
WATER-IN-FUEL (WIF) warning light should come on for 2 seconds to
perform bulb and wiring circuit test and then go off. WATER-IN-FUEL
(WIF) warning light is located on instrument panel, just below the
Page 292 of 1691
F - B ASIC T E STIN G - R W D - G ASO LIN E
1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Basic Diagnostic Procedures Trucks & RWD Vans
Dakota, Durango, Ram Pickup, Ram Van, Ram Wagon
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
The following diagnostic steps will help prevent overlooking
a simple problem. This is also where to begin diagnosis for a no-start
condition.
The first step in diagnosing any driveability problem is
verifying the customer's complaint with a test drive under the
conditions the problem reportedly occurred.
Before entering self-diagnostics, perform a careful and
complete visual inspection. Most engine control problems result from
mechanical breakdowns, poor electrical connections or
damaged/misrouted vacuum hoses. Before condemning the computerized
system, perform each test listed in this article.
NOTE: Perform all voltage tests with a Digital Volt-Ohmmeter (DVOM)\
with a minimum 10-megohm input impedance, unless stated
otherwise in test procedure.
PRELIMINARY INSPECTION & ADJUSTMENTS
VISUAL INSPECTION
Visually inspect all electrical wiring, looking for chafed,
stretched, cut or pinched wiring. Ensure electrical connectors fit
tightly and are not corroded. Ensure vacuum hoses are properly routed
and are not pinched or cut. Inspect air induction system for possible
vacuum leaks.
MECHANICAL INSPECTION
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.
Check engine mechanical condition with a compression gauge,
vacuum gauge, or an engine analyzer. See engine analyzer manual for
specific instructions.
COMPRESSION SPECIFICATIONS
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Application Specification
Compression Ratio
Ram Pickup (8.0L) .......................................... 8.4:1\
All Others ................................................. 9.1:1
Normal Compression Pressure .................................... ( 1)
Page 344 of 1691
specifications.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - If a sensor is not adjustable, further inspection is
required to identify and correct cause.
( 2) - Determine cause and correct prior to repair or
replacement of part.
( 3) - Determine source of contamination, such as metal
particles or water. Require repair or replacement.
( 4) - Inoperative includes intermittent operation or out of OEM
specification. Some components may be serviceable; check
for accepted cleaning procedure.
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STEEL BRAKE LINES
STEEL BRAKE LINE 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.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Fitting incorrect (for
example, compression
fitting) ............... B ............ Require replacement.
Flare type incorrect .... B .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Line material incorrect
(copper, etc.) ......... B ............ Require replacement.
Restricted .............. A ............ Require replacement.
Routed incorrectly ...... B ..... Require routing correction.
Rust-pitted ............. 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ............ Require replacement.
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STOPLIGHT SWITCHES
See BRAKE STOPLIGHT SWITCHES .
SWITCHES
NOTE: Copied from Electrical UIGs & added "float saturated" from
old fluid level sensor switches.
STEEL BRAKE LINE INSPECTION
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Page 660 of 1691
Compression Ratio ............................................ 9.1:1
Fuel System .................................................... PFI
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GENERAL SPECIFICATIONS (5.2L) \
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Application Specification
Displacement .................................... 318 Cu. In. (5.2L)\
Bore ............................................... 3.91" (99.3 mm)\
Stroke ............................................. 3.31" (84.1 mm)\
Compression Ratio ............................................ 9.1:1
Fuel System .................................................... PFI
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GENERAL SPECIFICATIONS (5.9L) \
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Application Specification
Displacement .................................... 360 Cu. In. (5.9L)\
Bore .............................................. 4.00" (101.6 mm)\
Stroke ............................................. 3.58" (90.9 mm)\
Compression Ratio ............................................ 9.1:1
Fuel System .................................................... PFI
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CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS \
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Application In. (mm)\
Crankshaft End Play
Standard ..................................... .002-.007 (.05-.18)\
Wear Limit ............................................ .010 (.25)\
Main Bearings
Journal Diameter
3.9L & 5.2L ....................... 2.4995-2.5005 (63.487-63.513)\
5.9L .............................. 2.8095-2.8105 (71.361-71.387)\
Journal Out-Of-Round .................................. .001 (.03)\
Journal Taper ......................................... .001 (.03)\
Oil Clearance
Journal No. 1
Standard .............................. .0005-.0015 (.013-.038)\
Wear Limit ....................................... .0015 (.038)\
All Others
Standard .............................. .0005-.0020 (.013-.051)\
Wear Limit ....................................... .0025 (.064)\
Connecting Rod Bearings
Journal Diameter ..................... 2.124-2.125 (53.950-53.975)\
Journal Out-Of-Round .................................. .001 (.03)\
Journal Taper ......................................... .001 (.03)\
Oil Clearance
Standard ................................ .0005-.0022 (.013-.056)\
Wear Limit ......................................... .0025 (.064)\
Side Play .................................... .006-.014 (.15-.36)\
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PISTONS, PINS & RINGS \
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Application In. (mm)\
Piston Clearance ........................... .0005-.0015 (.013-.038)\
Pins
Diameter
Page 822 of 1691
complete cooling system. Test components as follows, following tool
manufacturer's instructions.
Radiator Cap
Visually inspect radiator cap, then dip cap into water and
connect to tester. Pump tester to bring pressure to upper limit of cap
specification. If cap fails to hold pressure, replace cap.
Fig. 2: Testing Radiator Pressure Cap
Cooling System
1) With engine off, wipe radiator filler neck seat clean.
Fill radiator to correct level. Attach tester to radiator and pump
until pressure is at upper level of radiator rating.
2) If pressure drops, inspect for external leaks. If no leaks
are apparent, detach tester and run engine until normal operating
temperature is reached. Reattach tester and observe. If pressure
builds up immediately, a possible leak exists from a faulty head
gasket or crack in head or block.
NOTE: Pressure may build up quickly. Release any excess pressure
or cooling system damage may result.
3) If there is no immediate pressure build up, pump tester to
within system pressure range (on radiator cap). Vibration of gauge
pointer indicates compression or combustion leak into cooling system.
Isolate leak by shorting each spark plug wire to cylinder block. Gauge
pointer should stop or decrease vibration when leaking cylinder is
shorted.
Page 964 of 1691
Courtesy of Chrysler Corp.
Fig. 20: Locating Crankshaft Position Sensor (Ram Pickup 8.0L)
Courtesy of Chrysler Corp.
DISTRIBUTOR
Removal (Dakota 2.5L)
1) Disconnect negative battery cable. Remove air inlet duct
between throttle body and air cleaner assembly. Remove distributor
cap. Disconnect electrical connector for distributor.
2) Remove spark plug from cylinder No. 1 at timing chain end
of engine. Rotate crankshaft clockwise (viewed from front of engine)
until cylinder No. 1 is at Top Dead Center (TDC) on compression stroke\
and timing mark on vibration damper aligns with "0" degree timing mark
on timing chain cover. DO NOT rotate crankshaft counterclockwise to
align timing marks.
3) Remove distributor hold-down bolt and hold-down clamp.
Remove distributor with gasket from cylinder block.
Page 966 of 1691
rotate crankshaft clockwise (viewed from front of engine) until
cylinder No. 1 is at Top Dead Center (TDC) on compression stroke and
timing mark on vibration damper aligns with "0" degree timing mark on
timing chain cover. DO NOT rotate crankshaft counterclockwise to align
timing marks. Go to next step.
3) Check position of slot in oil pump drive gear in cylinder
block. The slot in oil pump drive gear should be at approximately the
10 o'clock position. Rotate oil pump drive gear if necessary.
4) If installing a factory replacement distributor, go to
next step. If installing original or used distributor, remove camshaft
position sensor from distributor. See Fig. 13. Rotate distributor
shaft and install a 3/16" (4.76 mm) diameter drift through proper
alignment hole in plastic ring and into access hole in bottom of
distributor housing. See Fig. 22. This prevents distributor shaft from
rotating. Go to next step.
CAUTION: There are 4 different alignment holes in the plastic ring.
Ensure proper alignment hole is used when installing drift
into plastic ring and distributor housing.
Fig. 22: Locating Alignment Hole On Plastic Ring (Dakota 2.5L)
Courtesy of Chrysler Corp.
5) Ensure distributor mounting area on cylinder block is
clean. Install NEW gasket on distributor. Install distributor rotor on
distributor shaft. Position distributor so center of hold-down bolt
area on distributor housing is at 1 o'clock position on cylinder
Page 967 of 1691
block. Install distributor so distributor shaft engages with slot in
oil pump drive gear. It may be necessary to slightly rotate
distributor during installation.
6) When distributor is fully seated, the distributor rotor
should be at 3 o'clock position and center of hold-down bolt area on
distributor housing should align with distributor hold-down bolt area
on cylinder block.
7) Install hold-down clamp and distributor hold-down bolt.
Tighten distributor hold-down bolt to specification. See TORQUE
SPECIFICATIONS.
8) If installing a factory replacement distributor, remove
plastic alignment pin from distributor housing. If installing original
or used distributor, remove drift from distributor housing and
reinstall camshaft position sensor. On all applications, install
distributor cap and remaining components. Base ignition timing is
nonadjustable, as ignition timing and timing advance are controlled by
the Powertrain Control Module (PCM).
Removal (Dakota 3.9L, 5.2L & 5.9L, Durango, Ram Pickup 3.9L,
5.2L & 5.9L, Ram Van & Ram Wagon)
1) Disconnect negative battery cable. On Ram Van and Ram
Wagon, remove engine cover. On all models, remove air cleaner
assembly. Remove distributor cap. Disconnect electrical connector for
distributor.
2) Rotate crankshaft clockwise (viewed from front of engine)\
until cylinder No. 1 is at Top Dead Center (TDC) on compression stroke\
and timing mark on vibration damper aligns with TDC timing mark on
timing chain cover. Cylinder No. 1 is the front cylinder on driver's
side of engine.
3) Ensure distributor rotor aligns with cylinder No. 1
alignment mark on camshaft position sensor. See Fig. 23. If
distributor rotor is not properly aligned, rotate crankshaft clockwise
one full revolution. Ensure distributor rotor aligns with terminal for
cylinder No. 1 on distributor cap.
4) Scribe a mark on distributor and adjacent component to
indicate rotor and distributor housing position for installation
reference. Remove distributor hold-down bolt and hold-down clamp.
Remove distributor with "O" ring from cylinder block.
Fig. 23: Aligning Distributor Rotor With Camshaft Position Sensor
(Dakota 3.9L, 5.2L & 5.9L, Durango, Ram Pickup 3.9L, 5.2L & 5.9L, Ram
Van & Ram Wagon)
Courtesy of Chrysler Corp.
Page 968 of 1691
Installation
1) If engine has not been rotated after removing distributor,
go to next step. If engine was rotated after removing distributor,
rotate crankshaft clockwise (viewed from front of engine) until
cylinder No. 1 is at Top Dead Center (TDC) on compression stroke and
timing mark on vibration damper aligns with TDC timing mark on timing
chain cover. Go to next step.
2) Ensure distributor mounting area on cylinder block is
clean. Install NEW "O" ring on distributor if necessary. Apply light
coat of engine oil on "O" ring.
3) Position distributor rotor so it aligns with terminal for
cylinder No. 1 on distributor cap. Install distributor. Ensure
distributor engages with slot in oil pump drive gear. Install hold-
down clamp and distributor hold-down bolt. DO NOT tighten distributor
hold-down bolt at this time.
4) Rotate distributor until distributor rotor aligns with
cylinder No. 1 alignment mark on camshaft position sensor. See Fig. 23
. Tighten distributor hold-down bolt to specification. See TORQUE
SPECIFICATIONS. To install remaining components, reverse removal
procedure.
5) Base ignition timing is nonadjustable. Base ignition
timing and timing advance are controlled by the Powertrain Control
Module (PCM). Distributor position is used to determine the fuel
system synchronization. To check for correct distributor position and
fuel system synchronization, see FUEL SYSTEM SYNCHRONIZATION under
FUEL SYSTEM in ON-VEHICLE ADJUSTMENTS article.
IGNITION COIL
Removal & Installation (Dakota 2.5L)
Ignition coil is located on side of engine, near distributor.
Service procedure is primarily an unbolt and bolt-on procedure.
Tighten ignition coil retaining bolts or nuts to specification. See
TORQUE SPECIFICATIONS.
Removal & Installation (Dakota 3.9L, 5.2L & 5.9L, Durango &
Ram Van/Wagon)
1) Ignition coil is located on front of passenger's side
cylinder head. Disconnect spark plug wires and electrical connector
from ignition coil.
CAUTION: Ignition coil-to-cylinder head mounting bracket bolts hold
the idler pulley for the accessory drive belt, as these bolts
are under tension. If necessary to remove these bolts,
accessory drive belt must be removed first.
2) Remove ignition coil retaining bolts or nuts with ignition
coil from the ignition coil mounting bracket. DO NOT remove ignition
coil-to-cylinder head mounting bracket bolts, as these bolts are under
tension.
3) To install, reverse removal procedure. Tighten ignition
coil retaining bolts or nuts to specification. See TORQUE
SPECIFICATIONS.
Removal & Installation (Ram Pickup 3.9L, 5.2L & 5.9L)
1) On 3.9L, 5.2L and 5.9L with light-duty emissions, ignition
coil is located on front of passenger's side cylinder head. On 5.9L
with heavy-duty emissions, ignition coil is located on top of air
injection pump. On all models, disconnect spark plug wires and
electrical connector from ignition coil.
CAUTION: On 3.9L, 5.2L and 5.9L with light-duty emissions, ignition
coil-to-cylinder head mounting bracket bolts hold the idler