check engine DODGE RAM 1999 Service Repair Manual

Fig. 18: Measuring Connecting Rod Side Clearance - Typical
This Graphic For General Information Only
Check for improper bearing installation, wrong bearing cap
or insufficient bearing clearance if side clearance is insufficient.
Connecting rod may require machining to obtain proper clearance.
Excessive clearance usually indicates excessive wear at crankshaft.
Crankshaft must be repaired or replaced.
MAIN & CONNECTING ROD BEARING CLEARANCE
Plastigage Method
Plastigage method may be used to determine bearing clearance.
Plastigage can be used with an engine in service or during reassembly.
Plastigage material is oil soluble.
Ensure journals and bearings are free of oil or solvent.
Oil or solvent will dissolve material and false reading will be
obtained. Install small piece of Plastigage along full length of
bearing journal. Install bearing cap in original location. Tighten
bolts to specification.
CAUTION: DO NOT rotate crankshaft while Plastigage is installed.
Bearing clearance will not be obtained if crankshaft is
rotated.
Remove bearing cap. Compare Plastigage width with scale on
Plastigage container to determine bearing clearance. See Fig. 19.
Rotate crankshaft 90 degrees. Repeat procedure. this is done to check
journal eccentricity. This procedure can be used to check oil
clearance on both connecting rod and main bearings.

CRANKSHAFT & MAIN BEARINGS
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
REMOVAL
Ensure all main bearing caps are marked for location on
cylinder block. Some main bearing caps have an arrow stamped on it
which must face front of engine. Remove main bearing cap bolts. Remove
main bearing caps. Carefully remove crankshaft. Use care not to bind
crankshaft in cylinder block during removal.
CLEANING & INSPECTION
Thoroughly clean crankshaft using solvent. Dry with
compressed air. Ensure all oil passages are clear and free of sludge,
rust, dirt, and metal chips.
Inspect crankshaft for scoring and nicks. Inspect crankshaft
for cracks using Magnaflux procedure. Inspect rear seal area for
grooving or damage. Inspect bolt hole threads for damage. If pilot
bearing or bushing is used, check pilot bearing or bushing fit in
crankshaft. Inspect crankshaft gear for damaged or cracked teeth.
Replace gear if damaged. Check that oil passage plugs are tight (if
equipped).
Using micrometer, measure all journals in 4 areas to
determine journal taper, out-of-round and undersize. See Fig. 20.
Some crankshafts can be reground to the next largest undersize,
depending on the amount of wear or damage. Crankshafts with rolled
fillet cannot be reground and must be replaced.
Fig. 20: Measuring Crankshaft Journal - Typical
This Graphic For General Information Only
Crankshaft journal runout should be checked. Install
crankshaft in "V" blocks or bench center. Position dial indicator

with tip resting on the main bearing journal area. See Fig. 21.
Rotate crankshaft and note reading. Journal runout must not exceed
specification. Repeat procedure on all main bearing journals.
Crankshaft must be replaced if runout exceeds specification.
Fig. 21: Measuring Crankshaft Main Bearing Journal Runout - Typical
This Graphic For General Information Only
INSTALLATION
Install upper main bearing in cylinder block. Ensure lock
tab is properly located in cylinder block. Install bearings in main
bearing caps. Ensure all oil passages are aligned. Install rear seal
(if removed).
Ensure crankshaft journals are clean. Lubricate upper main
bearings with clean engine oil. Carefully install crankshaft. Check
each main bearing clearance using Plastigage method. See
MAIN & CONNECTING ROD BEARING CLEARANCE in this article.
Once clearance is checked, lubricate lower main bearing and
journals. Install main bearing caps in original location. Install rear
seal in rear main bearing cap (if removed). Some rear main bearing
caps require sealant to be applied in corners to prevent oil leakage.
Install and tighten all bolts except thrust bearing cap to
specification. Tighten thrust bearing cap bolts finger tight only.
Thrust bearing must be aligned. On most applications, crankshaft
must be moved rearward then forward. Procedure may vary with
manufacturer. Thrust bearing cap is then tighten to specification.
Ensure crankshaft rotates freely. Crankshaft end play should be
checked. See CRANKSHAFT END PLAY in this article.
CRANKSHAFT END PLAY
Dial Indicator Method
Crankshaft end play can be checked using dial indicator.
Mount dial indicator on rear of cylinder block. Position dial
indicator tip against rear of crankshaft. Ensure tip is resting
against flat surface.
Pry crankshaft rearward. Adjust dial indicator to zero.

CYLINDER BLOCK
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
BLOCK CLEANING
Only cast cylinder blocks should be hot tank cleaned.
Aluminum cylinder blocks should be cleaned using cold tank method.
Cylinder block is cleaned in order to remove carbon deposits, gasket
residue and water jacket scale. Remove oil galley plugs, freeze plugs
and cam bearings prior to block cleaning.
BLOCK INSPECTION
Visually inspect the block. Check suspected areas for cracks
using the Dye Penetrant inspection method. Block may be checked for
cracks using the Magnaflux method.
Cracks are most commonly found at the bottom of the
cylinders, the main bearing saddles, near expansion plugs and between
the cylinders and water jackets. Inspect lifter bores for damage.
Inspect all head bolt holes for damaged threads. Threads should be
cleaned using tap to ensure proper head bolt torque. Consult machine
shop concerning possible welding and machining (if required).
CYLINDER BORE INSPECTION
Inspect the bore for scuffing or roughness. Cylinder bore
is dimensionally checked for out-of-round and taper using dial bore
gauge. For determining out-of-round, measure cylinder parallel and
perpendicular to the block centerline. Difference in the 2 readings
is the bore out-of-round. Cylinder bore must be checked at top, middle
and bottom of piston travel area.
Bore taper is obtained by measuring bore at the top and
bottom. If wear has exceeded allowable limits, block must be honed
or bored to next available oversize piston dimension.
CYLINDER HONING
Cylinder must be properly honed to allow new piston rings to
properly seat. Cross-hatching at correct angle and depth is critical
to lubrication of cylinder walls and pistons.
A flexible drive hone and power drill are commonly used.
Drive hone must be lubricated during operation. Mix equal parts of
kerosene and SAE 20w engine oil for lubrication.
Apply lubrication to cylinder wall. Operate cylinder hone
from top to bottom of cylinder using even strokes to produce 45 degree
cross-hatch pattern on the cylinder wall. DO NOT allow cylinder hone
to extend below cylinder during operation.
Recheck bore dimension after final honing. Wash cylinder
wall with hot soapy water to remove abrasive particles. Blow dry with
compressed air. Coat cleaned cylinder walls with lubricating oil.
DECK WARPAGE
Check deck for damage or warped head sealing surface. Place
a straightedge across gasket surface of the deck. Using feeler gauge,
measure clearance at center of straightedge. Measure across width and

NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
CLEANING & INSPECTION
Clean camshaft with solvent. Ensure all oil passages are
clear. Inspect cam lobes and bearing journals for pitting, flaking or
scoring. Using micrometer, measure bearing journal O.D.
Support camshaft at each end with "V" blocks. Position dial
indicator with tip resting on center bearing journal. Rotate camshaft
and note reading. If reading exceeds specification, replace camshaft.
Check cam lobe lift by measuring base circle of camshaft
using micrometer. Measure again at 90 degrees to tip of cam lobe. Cam
lift can be determined by subtracting base circle diameter from tip of
cam lobe measurement.
Different lift dimensions are given for intake and exhaust
cam lobes. Reading must be within specifications. Replace camshaft if
cam lobes or bearing journals are not within specifications.
Inspect camshaft gear for chipped, eroded or damaged teeth.
Replace gear if damaged. On camshafts using thrust plate, measure
distance between thrust plate and camshaft shoulder. Replace thrust
plate if not within specification.
CAMSHAFT BEARINGS
Removal & Installation
Remove the camshaft rear plug. The camshaft bearing remover
is assembled with its shoulder resting on the bearing to be removed
according to manufacturer's instructions. Tighten puller nut until
bearing is removed. Remove remaining bearings, leaving front and rear
bearings until last. These bearings act as guide for camshaft bearing
remover.
To install new bearings, puller is rearranged to pull
bearings toward the center of block. Ensure all lubrication passages
of bearing are aligned with cylinder block. Coat new camshaft rear
plug with sealant. Install camshaft rear plug. Ensure plug is even
in cylinder block.
CAMSHAFT INSTALLATION
Lubricate bearing surfaces and cam lobes with ample amount of
Molykote or camshaft lubricant. Carefully install camshaft. Use care
not to damage bearing journals during installation. Install thrust
plate retaining bolts (if equipped). Tighten bolts to specification.
On overhead camshafts, install bearing caps in original location.
Tighten bolts to specification. Check end play.
CAMSHAFT END PLAY
Using dial indicator, check end play. Position dial indicator
on front of engine block. Position indicator tip against camshaft.
Push camshaft toward rear of engine and adjust indicator to zero.
Move camshaft forward and note reading. Camshaft end play
must be within specification. End play may be adjusted by relocating
gear, shimming thrust plate or replacing thrust plate depending on
manufacturer.
TIMING CHAINS & BELTS

* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
TIMING CHAINS
Timing chains will stretch during operation. Limits are
placed upon amount of stretch before replacement is required. Timing
chain stretch will alter ignition timing and valve timing.
To check timing chain stretch, rotate crankshaft to eliminate
slack from one side of timing chain. Mark reference point on cylinder
block. Rotate crankshaft in opposite direction to eliminate slack from
remaining side of timing chain. Force other side of chain outward
and measure distance between reference point and timing chain. See
Fig. 23 . Replace timing chain and gears if not within specification.
Fig. 23: Measuring Timing Chain Stretch - Typical
This Graphic For General Information Only
Timing chains must be installed so that timing marks on
camshaft gear and crankshaft gear are aligned according to

* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
TIMING GEAR BACKLASH & RUNOUT
On engines where camshaft gear operates directly on
crankshaft gear, gear backlash and runout must be checked. To check
backlash, install dial indicator with tip resting on tooth of camshaft
gear. Rotate camshaft gear as far as possible. Adjust indicator to
zero. Rotate camshaft gear in opposite direction as far as possible
and note reading.
To determine timing gear runout, mount dial indicator with
tip resting on face edge of camshaft gear. Adjust indicator to zero.
Rotate camshaft gear 360 degrees and note reading. If backlash or
runout exceed specifications, replace camshaft and/or crankshaft
gear.
REAR MAIN OIL SEAL
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
INSTALLATION
One-Piece Type Seal
For one-piece type oil seal installation, coat block contact
surface of seal with sealer if seal is not factory coated. Ensure seal
surface is free of burrs. Lubricate seal lip with engine oil and press
seal into place using proper oil seal installer. See Fig. 27.
Fig. 27: Installing Typical One-Piece Oil Seal
This Graphic For General Information Only
Rope Type Seal
For rope type rear main oil seal installation, press seal

Engine pre-oiling can be done using pressure oiler (if
available). Connect pressure oiler to cylinder block oil passage
such as oil pressure sending unit. Operate pressure oiler long enough
to ensure correct amount of oil has filled crankcase. Check oil level
while pre-oiling.
If pressure oiler is not available, disconnect ignition
system. Remove oil pressure sending unit and replace with oil pressure
test gauge. Using starter motor, rotate engine starter until gauge
shows normal oil pressure for several seconds. DO NOT crank engine
for more than 30 seconds to avoid starter motor damage.
Ensure oil pressure has reached the most distant point from
the oil pump. Reinstall oil pressure sending unit. Reconnect ignition
system.
INITIAL START-UP
Start the engine and operate engine at low speed while
checking for coolant, fuel and oil leaks. Stop engine. Recheck coolant
and oil level. Adjust if necessary.
CAMSHAFT
Break-in procedure is required when a new or reground
camshaft has been installed. Operate and maintain engine speed between
1500-2500 RPM for approximately 30 minutes. Procedure may vary due to
manufacturers recommendations.
PISTON RINGS
Piston rings require a break-in procedure to ensure seating
of rings to cylinder walls. Serious damage may occur to rings if
correct procedures are not followed.
Extremely high piston ring temperatures are produced obtained
during break-in process. If rings are exposed to excessively high RPM
or high cylinder pressures, ring damage can occur. Follow piston ring
manufacturer's recommended break-in procedure.
FINAL ADJUSTMENTS
Check or adjust ignition timing and dwell (if applicable).
Adjust valves (if necessary). Adjust carburetion or injection idle
speed and mixture. Retighten cylinder heads (if required). If
cylinder head or block is aluminum, retighten bolts when engine is
cold. Follow the engine manufacturer's recommended break-in procedure
and maintenance schedule for new engines.
NOTE: Some manufacturer's require that head bolts be retightened
after specified amount of operation. This must be done to
prevent head gasket failure.


* E N G IN E S YSTE M S U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
Engine Performance and Maintenance Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
Engine Assemblies
CYLINDER HEAD ASSEMBLIES
LONG BLOCK ASSEMBLIES
SHORT BLOCK ASSEMBLIES
Engine Components
ACCELERATOR PEDAL POSITION SENSORS
ACCESSORY BELTS
ACCESSORY PULLEYS
ACTUATORS
AIR CONDITIONING CYCLING SWITCHES
AIR CONDITIONING PRESSURE SENSORS
AIR DUCTS AND TUBES
AIR FILTER ELEMENTS
AIR FILTER GASKETS
AIR FILTER HOUSINGS AND GASKETS
AIR FUEL RATIO SENSORS
AIR INJECTION CONTROL SOLENOIDS
AIR PLENUMS
AIR PUMP BELTS
AIR PUMPS (ELECTRIC-DRIVEN)
AIR TUBES
ASPIRATOR, CHECK AND DECEL VALVES
BAFFLES
BALLAST PRIMARY SUPPLY RESISTOR WIRES
BALLAST RESISTORS AND PRIMARY SUPPLY RESISTOR WIRES
BAROMETRIC PRESSURE SENSORS
BATTERIES
BATTERY CABLES, WIRES AND CONNECTORS
BATTERY CONNECTORS
BATTERY TRAYS AND HOLD DOWN HARDWARE
BATTERY WIRES
BELT-DRIVEN AIR PUMPS
BELT IDLER ASSEMBLIES (ACCESSORY AND CAM BELTS)
BELT TENSIONERS (ACCESSORY AND CAM BELTS)
BOOST CONTROL MECHANISMS
CAMSHAFT POSITION SENSORS
CARBURETORS AND CHOKES
CASTING CORE PLUGS AND EXPANSION PLUGS
CHARGE AIR COOLERS "INTERCOOLERS" (CAC)
CHECK VALVES
CHOKES

CLUTCH PEDAL POSITION SWITCHES
COLD START INJECTORS
CONNECTORS
COOLANT
COOLANT RECOVERY TANKS
COOLING FAN MOTOR MODULES
COOLING FAN MOTOR RELAYS AND MODULES
COOLING FAN MOTOR RESISTORS
COOLING FAN MOTOR SENSORS AND SWITCHES
COOLING FAN MOTOR SWITCHES
COOLING FAN MOTORS
CRANKSHAFT POSITION SENSORS
DECEL VALVES
DEFLECTORS
DIP STICKS AND TUBES
DIP STICK TUBES
DISTRIBUTOR ADVANCES AND RETARDERS (MECHANICAL AND VACUUM)
DISTRIBUTOR BOOTS AND SHIELDS
DISTRIBUTOR CAPS
DISTRIBUTOR RETARDERS (MECHANICAL AND VACUUM)
DISTRIBUTOR ROTORS
DISTRIBUTOR SHIELDS
DISTRIBUTORS
EARLY FUEL EVAPORATION VALVES (HEAT RISER ASSEMBLIES)
EGR COOLERS
EGR EXHAUST MANIFOLD PASSAGES
EGR INTAKE AND EXHAUST MANIFOLD PASSAGES
EGR PLATES AND COOLERS
ELECTRONIC SPARK CONTROL MODULES
ELECTRONIC TRANSMISSION CONTROL DEVICES
ELECTRONIC TRANSMISSION FEEDBACK DEVICES
ENGINE COOLANT TEMPERATURE SENSORS
ENGINE COOLING SYSTEMS
ENGINE COVERS (OIL PAN, VALVE COVER, TIMING COVER)
ENGINE OIL
ENGINE OIL CANISTERS
ENGINE OIL COOLERS (EXTERNAL)
ENGINE OIL DRAIN PLUGS AND GASKETS
ENGINE OIL FILTERS AND CANISTERS
ENGINE OIL GASKETS
ENGINE OIL PRESSURE GAUGES (MECHANICAL)
EVAPORATIVE EMISSION (EVAP) CANISTER FILTERS
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE DEVICES
EVAPORATIVE EMISSION (EVAP) CANISTERS
EVAPORATIVE EMISSION (EVAP) FEEDBACK DEVICES
EXHAUST GAS RECIRCULATION DEVICES
EXHAUST GAS RECIRCULATION FEEDBACK DEVICES
EXPANSION PLUGS
FAN CONTROL SENSORS
FUEL
FUEL ACCUMULATORS AND DAMPERS
FUEL AND COLD START INJECTORS
FUEL DAMPERS
FUEL DELIVERY CHECK VALVES
FUEL DISTRIBUTORS (BOSCH CIS)
FUEL FILLER NECKS AND RESTRICTORS
FUEL FILTERS
FUEL INJECTORS
FUEL LEVEL SENDERS7
FUEL PRESSURE REGULATORS
FUEL PUMPS (IN-TANK AND EXTERNAL, ELECTRICAL OR MECHANICAL)
FUEL RAILS
FUEL RESTRICTORS