check engine DODGE RAM 1999 Service Repair Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 797 of 1691
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Determine source of contamination, such as engine coolant,
fuel, metal particles, or water. Require repair or
replacement.
( 3) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable;
check for accepted cleaning procedure.
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THROTTLE POSITION SWITCHES
THROTTLE POSITION SWITCH INSPECTION \
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Condition Code Procedure
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of hardware.
Attaching hardware
threads stripped
(threads missing) ...... A .. Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. B ........... ( 2) Require repair or
replacement. Further
inspection required.
Missing ................. C ............ Require replacement.
Resistance out of
specification .......... B .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Page 803 of 1691
(2) - Determine source of contamination, such as engine coolant,
fuel, metal particles, or water. Require repair or
replacement.
( 3) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable;
check for accepted cleaning procedure.
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VACUUM TUBES
See VACUUM HOSES, TUBES AND CONNECTIONS (NON-METALLIC) .
VEHICLE SPEED SENSORS
VEHICLE SPEED SENSOR INSPECTION \
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Condition Code Procedure
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of hardware.
Attaching hardware
threads stripped
(threads missing) ...... A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Contaminated ............ A ........... ( 2) Require repair or
replacement.
Inoperative ............. B ........... ( 3) Require repair or
replacement. Further
inspection required.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Resistance out of
specification .......... B .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Page 804 of 1691
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Determine source of contamination, such as engine coolant,
fuel, metal particles, or water. Require repair or
replacement.
( 3) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable;
check for accepted cleaning procedure.
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VOLUME AIR FLOW SENSORS
VOLUME AIR FLOW SENSOR INSPECTION \
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Condition Code Procedure
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of hardware.
Attaching hardware
threads stripped
(threads missing) ...... A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Contaminated ............ A ........... ( 2) Require repair or
replacement.
Inoperative ............. B ........... ( 3) Require repair or
replacement. Further
inspection required.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Resistance out of
specification .......... B .. Require repair or replacement.
Restricted, affecting
performance ............ A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Page 805 of 1691
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Determine source of contamination, such as engine coolant,
fuel, metal particles, or water. Require repair or
replacement.
( 3) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable;
check for accepted cleaning procedure.
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WASTE GATE CONTROL SOLENOIDS
WASTE GATE CONTROL SOLENOID INSPECTION \
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Condition Code Procedure
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of hardware.
Attaching hardware
threads stripped
(threads missing) ...... A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Contaminated ............ A ........... ( 2) Require repair or
replacement.
Inoperative ............. B ........... ( 3) Require repair or
replacement. Further
inspection required.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Resistance out of
specification .......... B .. Require repair or replacement.
Restricted, affecting
performance ............ A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Page 806 of 1691
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Determine source of contamination, such as engine coolant,
fuel, metal particles, or water. Require repair or
replacement.
( 3) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable;
check for accepted cleaning procedure.
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WASTE GATES AND BOOST CONTROL MECHANISMS
WASTE GATE AND BOOST CONTROL MECHANISM INSPECTION \
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Condition Code Procedure
Boost pressure
incorrect .............. A ........... ( 1) Require repair or
replacement. Further
inspection required.
Leaking ................. A .. Require repair or replacement.
( 1) - Incorrect boost pressure includes intermittent operation
or out of OEM specification.
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WATER PUMPS (ELECTRIC)
WATER PUMP (ELECTRIC) 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.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ ( 2) Require replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 ............ Suggest replacement.
Rotation incorrect for
application ............ B .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Page 821 of 1691
REFILLING
To prevent air from being trapped in engine block, engine
should be running when refilling cooling system. After system is full,
continue running engine until thermostat is open, then recheck fill
level. Do not overfill system.
TESTING
THERMOSTAT
1) Visually inspect thermostat for corrosion and proper
sealing of valve and seat. If okay, suspend thermostat and thermometer
in a 50/50 mixture of coolant and water. See Fig. 1. Do not allow
thermostat or thermometer to touch bottom of container. Heat water
until thermostat just begins to open.
2) Read temperature on thermometer. This is the initial
opening temperature and should be within specification. Continue
heating water until thermostat is fully open and note temperature.
This is the fully opened temperature. If either reading is not to
specification, replace thermostat.
Fig. 1: Testing Thermostat in Anti-Freeze/Water Solution
PRESSURE TESTING
A pressure tester is used to check both radiator cap and
Page 824 of 1691
pointer is at one o'clock position. Push in on knob slightly and
continue rotating knob to its full clockwise stop. Place knob pointer
at a position about .32" (8 mm) beyond end of Red stripe. Release
knob. If knob is pointing at about .32" (8 mm) beyond end of Red
stripe, go to next step. If knob is not pointing at about .32" (8 mm)
beyond end of Red stripe, go back to step 2) and repeat adjustment
procedure.
4) Rotate temperature control knob counterclockwise so that
knob pointer is at 12 o'clock position. Push temperature control knob
straight into heater control panel until perimeter of knob (not knob
pointer) is flush with base of heater control panel.
5) Rotate temperature control knob to its full clockwise
stop. Release knob. Knob pointer should be aimed at end of Red stripe.
If knob is pointed at end of Red stripe, go to next step. If knob is
not pointed at end of Red stripe, go back to step 2) and repeat
adjustment procedure.
6) Rotate temperature control knob to its full
counterclockwise stop. Release knob. If knob springs back, self-
adjuster clip securing temperature control cable to blend-air door
lever is improperly installed. See TEMPERATURE CONTROL CABLE R & I
under REMOVAL & INSTALLATION. If knob does not springs back,
temperature control cable adjustment is complete.
TROUBLE SHOOTING
HEATER PERFORMANCE
Check cooling system. Check serpentine drive belt tension.
Check radiator and radiator fan operation. Ensure that accessory
vacuum supply line is connected at power brake booster (Dakota) or
engine vacuum source (except Dakota).
TESTING
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all SERVICE PRECAUTIONS and DISABLING &
ACTIVATING AIR BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY
article.
BLOWER MOTOR RELAYS
1) Blower motor relay is located in Power Distribution Center
(PDC). On Ram Van/Wagon, high speed blower motor relay is located in
engine compartment (on side of heater assembly). On all models,
disconnect negative battery cable. Remove blower motor relay. Using an
ohmmeter, check for continuity between terminals No. 87A and 30 of
relay. See Fig. 1. If continuity does not exist, replace relay. If
continuity exists, go to next step.
2) Using an ohmmeter, check for continuity between terminals
No. 30 and 87 of relay. If continuity exists, replace relay. If
continuity does not exist, go to next step.
3) Measure resistance between terminals No. 85 and 86 of
relay. Reading should be 70-80 ohms. If reading is not as specified,
replace relay. If reading is as specified, go to next step.
4) Using jumper wires, connect battery voltage to terminal
No. 86 and ground terminal No. 85. See Fig. 1. Check that continuity
exists between terminals No. 30 and 87. Check that continuity does not
exist between terminals No. 87A and 30. If continuity is not as
specified, replace blower motor relay. If continuity is as specified,
relay is okay.
Page 828 of 1691
1) Connect a vacuum gauge in line with Black heater vacuum
supply hose (located at tee near power brake booster, in engine
compartment). Position gauge so it can be viewed from passenger
compartment.
2) Start engine. While observing vacuum gauge, rotate mode
control knob to each mode position (one position at a time). Pause
after each selection. Vacuum gauge should drop then return to 8 in. Hg
shortly after each selection is made. If vacuum gauge reading is as
specified, go to next step. If gauge reading is not as specified,
check for vacuum leak in vacuum lines or heater control panel.
3) Move temperature control knob quickly to full hot and full
cold positions. A distinct sound of blend-air door hitting its stops
should be heard. No spring-back of knob should exist.
4) If temperature control knob operates as specified,
temperature control system is okay. If temperature control knob does
not operate as specified, check condition, routing, installation and
adjustment of temperature control cable. See
TEMPERATURE CONTROL CABLE ADJUSTMENT.
HEATER OUTPUT
1) Start engine. Allow engine to reach normal operating
temperature. With engine at idle, set controls to maximum heat, floor
and high blower positions. Using a thermometer, check air temperature
coming from floor vents. See HEATER OUTPUT TEMPERATURE table.
2) If floor outlet air temperature is lower than specified,
check cooling system and electric cooling fan. See ELECTRIC COOLING
FAN article.
3) Check that both return and supply heater hoses are hot. If
coolant return hose is much cooler than supply hose, repair coolant
obstruction in heater system. Check for air flow obstruction in heater
system. Check blend air door for proper operation.
HEATER OUTPUT TEMPERATURE
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Ambient Temp. F (C) Outlet Vent Temp. F (C)
Except Durango
60 (15.6) ............................................. 144 (62.2\
)
70 (21.1) ............................................. 147 (63.8\
)
80 (26.6) ............................................. 150 (65.5\
)
90 (32.2) ............................................. 153 (67.2\
)
Durango
60 (15.6) ............................................. 126 (52.2\
)
70 (21.1) ............................................. 133 (56.1\
)
80 (26.6) ............................................. 139 (59.4\
)
90 (32.2) ............................................. 144 (62.2\
)
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REMOVAL & INSTALLATION
* PLEASE READ THIS FIRST *
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all SERVICE PRECAUTIONS and DISABLING &
ACTIVATING AIR BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY
article.
BLEND AIR DOOR MOTOR
Removal & Installation (Ram Pickup)
Remove heater assembly. See HEATER ASSEMBLY. Remove blend air
Page 854 of 1691
IN STR UM EN T P A N EL - A N ALO G
1999 D odge P ic ku p R 1500
1999 ACCESSORIES & EQUIPMENT
CHRY - Analog Instrument Panels
Ram Pickup, Ram Van & Ram Wagon
DESCRIPTION & OPERATION
INSTRUMENT CLUSTER
All instrument cluster gauges are air core magnetic type.
Tachometer is optional. All gauges use data transferred on Chrysler
Collision Detection (CCD) bus. Instrument cluster incorporates a
Vacuum Fluorescent Display (VFD) for odometer display.
Brake warning light illuminates when ignition is on and
parking brake is applied. Brake warning light also illuminates if
brake hydraulic system failure occurs during service brake
application. Brake warning light bulb test occurs when ignition switch
is in START position.
Oil pressure warning light illuminates when engine oil
pressure is not sufficient to open oil pressure sending unit switch.
Oil pressure warning light bulb test occurs with ignition switch in
RUN position.
All instrument clusters include these analog gauges:
* Coolant Temperature Gauge
* Fuel Gauge
* Oil Pressure Gauge
* Speedometer
* Voltmeter
Instrument clusters include these indicator lights, if
vehicle is equipped with appropriate option:
* Air Bag
* Anti-Lock Brake System (ABS)
* Brake Warning
* Check Gauges
* Cruise On
* Headlight High Beam
* Low Fuel
* Low Washer Fluid
* CHECK ENGINE
* Overdrive Off
* Rear Wheel Anti-Lock (RWAL)
* Seat Belt Reminder
* Security
* Transmission Oil Temperature (A/T)
* Turn Signal
* Upshift (M/T)
* 4WD
SELF-DIAGNOSTIC SYSTEM
WARNING: Vehicle is equipped with an air bag system. To prevent air
bag deployment, disconnect negative battery cable and wait at
least 2 minutes before servicing instrument cluster. See
appropriate AIR BAG RESTRAINT SYSTEMS article.
CAUTION: When battery is disconnected, vehicle computer and memory
Page 860 of 1691
3) Turn ignition off. Disconnect washer fluid level sensor
connector. Install jumper wire between washer fluid level sensor
connector terminals. Turn ignition on. Low washer fluid level light
should illuminate. Disconnect jumper wire and light should go off. If
light performs as specified, replace washer fluid level sensor. If
light does not perform as specified, go to next step.
4) Turn ignition off. Check continuity between ground and
washer fluid level sensor connector Black wire. If continuity does not
exist, repair open Black wire between washer fluid level sensor and
ground. If continuity exists, go to next step.
5) Ensure washer fluid level sensor is still disconnected.
Turn ignition off. Remove instrument cluster. See INSTRUMENT CLUSTER
under REMOVAL & INSTALLATION. Check continuity between ground and
instrument cluster connector C2 terminal No. 2 (Black/White wire) on
Ram Pickup and terminal No. 9 (Black/Gray wire) on Ram Van and Ram
Wagon. If continuity does not exist, go to next step. If continuity
exists, repair short to ground in White/Black or Black/Gray wire
between instrument cluster and washer fluid level sensor.
6) Check continuity of Black/White wire on Ram Pickup or
Black/Gray wire on Ram Van and Ram Wagon between washer fluid level
sensor connector and instrument cluster connector C2 terminal No. 2 on
Ram Pickup or terminal No. 9 on Ram Van and Ram Wagon. See Fig. 1. If
continuity does not exist, repair open Black/White wire on Ram Pickup
or Black/Gray wire on Ram Van and Ram Wagon. If continuity exists,
replace bulb.
WAIT-TO-START LIGHT INOPERATIVE (RAM PICKUP - DIESEL)
1) Remove and inspect fuse No. 17 (10-amp) in junction block\
.
Junction block is located at left end cover of instrument panel. If
fuse is okay, go to next step. If fuse is blown, locate and repair
cause of blown fuse. Install new fuse and recheck system operation.
2) Turn ignition on. Measure voltage between ground and power
side of fuse No. 17. If battery voltage is present, go to next step.
If battery voltage is not present, locate and repair open circuit
between Power Distribution Center (PDC) and junction block.
3) Disconnect negative battery cable. Remove instrument
cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Check
for battery voltage between ground and instrument cluster connector C1
terminal No. 2 (Dark Blue/White wire). See Fig. 1. Turn ignition on.
If battery voltage exists, go to next step. If battery voltage does
not exist, repair open Dark Blue/White wire between junction block and
instrument cluster.
4) Turn ignition off. Disconnect Powertrain Control Module
(PCM) White connector C2. PCM is located at firewall in right side of
engine compartment. Connector C2 is center connector. Check continuity
between ground and instrument cluster connector C1 terminal No. 8
(Orange/Black wire). If continuity does not exist, go to next step. If\
continuity exists, repair short to ground in Orange/Black wire between
instrument cluster and ground.
5) Install instrument cluster. Connect battery cable. Install
jumper wire between PCM White connector C2 terminal No. 20
(Orange/Black wire) and ground. See Fig. 2. Turn ignition on. Wait-to-
start light should illuminate. If wait-to-start light illuminates, see
appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE section. If
wait-to-start light does not illuminate, see SELF-DIAGNOSTICS.