battery DODGE RAM 1999 Service Repair Manual

pump to drain the fuel tank, go to next step.
2) Disconnect fuel line from fuel rail. See FUEL LINE AT FUEL
RAIL. Connect Fuel Hose (6541, 6539, 6631 or 6923) for proper engine
application at fuel line fitting on fuel rail. Place remaining end of
fuel hose in an approved gasoline container.
3) Connect scan tool to Data Link Connector (DLC). DLC is a
16-pin connector attached to bottom of driver's side of the instrument
panel, just straight above the accelerator pedal. Using scan tool
manufacturer's instructions, activate the fuel pump and pump fuel from
fuel tank. Once fuel tank is empty, remove scan tool. Reinstall fuel
line on fuel rail using proper procedure. Go to step 5).
4) Release fuel pressure from fuel system. See FUEL SYSTEM
PRESSURE RELEASE. Ensure negative battery cable is disconnected.
Remove fuel tank cap to release any residual fuel tank pressure.
5) Raise and support vehicle. Disconnect the small vent hose
from fill and vent hose fitting assembly at driver's side frame rail.
Fill and vent hose fitting assembly is permanently attached on fuel
tank. See Fig. 30.
6) If fuel tank was previously drained, go to next step. If
fuel tank was not previously drained, siphon fuel from fuel tank into
an approved gasoline container by installing siphon hose in small vent
hose fitting on fill and vent hose fitting assembly. Go to next step.
7) Disconnect large fill hose from fill and vent hose fitting
assembly at driver's side frame rail. Fill and vent hose fitting
assembly is permanently attached on fuel tank. See Fig. 30.
8) Support fuel tank with transmission jack. Remove fuel tank
strap retaining nuts from L-shaped bolts securing fuel tank straps on
frame rail. Remove fuel tank straps.
CAUTION: Fill and vent hose fitting assembly must be released from
plastic shield before lowering fuel tank. Use care when
lowering fuel tank as not to damage fill and vent hose
fitting assembly or the fuel tank.
9) Fill and vent hose fitting assembly is permanently
attached on fuel tank and is protected from the frame by a plastic
shield. See Fig. 30. Push retaining tabs inward to release fill and
vent hose fitting assembly from the plastic shield before lowering the
fuel tank. See Fig. 38.
Fig. 38: Releasing Retaining Tabs From Plastic Shield (Ram Van &
Ram Wagon)
Courtesy of Chrysler Corp.
10) Slightly lower fuel tank while guiding fill and vent hose

fitting assembly out of the plastic shield. Use care not to damage
fill and vent fitting assembly. Disconnect fuel line from fuel
filter/fuel pressure regulator on fuel pump module using proper
procedure for fuel line disconnect fitting. See FUEL LINE DISCONNECT
FITTINGS. Fuel pump module is located on top of fuel tank. See Fig. 30
.
11) Disconnect electrical connector at fuel pump module.
Disconnect vapor hoses from rollover valves on top of fuel tank. See
Fig. 30 . Lower fuel tank from vehicle. Use care not to damage fill and
vent hose fitting assembly.
Installation
1) To install, reverse removal procedure. Install fuel lines
on fuel filter/fuel pressure regulator on fuel pump module using
proper procedure. See FUEL LINE DISCONNECT FITTINGS.
2) Ensure retaining tabs on fill and vent hose fitting
assembly fully engage the plastic shield. Tighten fuel tank strap
retaining nuts to specification. See TORQUE SPECIFICATIONS. Start
engine and check for fuel leaks.
FUEL RAIL & INJECTORS
Removal (Dakota 2.5L)
1) Release fuel pressure from fuel system. See FUEL SYSTEM
PRESSURE RELEASE. Ensure negative battery cable is disconnected.
2) Disconnect air inlet duct at throttle body for access to
fuel rail. Disconnect vent line from fuel damper at end of fuel rail
(if equipped).
3) Note electrical connector location on injectors for
installation reference. Disconnect electrical connectors at injectors.
Disconnect fuel line from fuel rail. See FUEL LINE AT FUEL RAIL.
Disconnect control cables at throttle body. Remove control cable
mounting bracket from intake manifold for access to fuel rail.
4) Remove fuel rail bolts. Ensure area around injectors and
intake manifold is clean. Using rocking motion, remove fuel rail with
injectors from intake manifold.
5) If removing injector from fuel rail, remove retaining clip
from fuel rail and injector. Retaining clip is located at top of
injector and fuel rail. Remove injector with "O" ring from fuel rail.
Installation
1) If installing injector on fuel rail, install NEW "O" ring
on injector. Coat "O" ring on injector with engine oil. Install
injector on fuel rail. Install retaining clip on injector and fuel
rail.
2) To install remaining components, reverse removal procedure
using NEW "O" ring at bottom of each injector. Coat "O" ring on
injector with engine oil before installing injectors and fuel rail.
3) Tighten fuel rail bolts to specification. See TORQUE
SPECIFICATIONS. Install fuel line on fuel rail using proper procedure.
See FUEL LINE AT FUEL RAIL. Start engine and check for leaks.
Removal (Dakota 3.9L, 5.2L & 5.9L, Durango, Ram Pickup 3.9L,
5.2L & 5.9L, Ram Van & Ram Wagon)
1) Release fuel pressure from fuel system. See FUEL SYSTEM
PRESSURE RELEASE. Ensure negative battery cable is disconnected.
2) On Ram Van and Ram Wagon, remove engine cover. On all
models, remove air cleaner. Remove throttle body from intake manifold.
See THROTTLE BODY. On A/C equipped models, remove A/C compressor-to-
intake manifold support brace at rear of A/C compressor.
3) On all models, note electrical connector location on
injectors for installation reference. Disconnect electrical connectors
at injectors. Disconnect any necessary wiring electrical connectors

for access to fuel rails and injectors.
CAUTION: Both fuel rails are serviced as an assembly. DO NOT attempt
to separate fuel rail from connecting fuel hose at rear of
each fuel rail. Connecting fuel hose does not use any form of
clamps on the hose. DO NOT use any clamps on connecting fuel
hose. When removing fuel rails with injectors, use care not
to bend connecting fuel hose.
4) Disconnect fuel line from fuel rail. See FUEL LINE AT FUEL
RAIL. Remove fuel rail bolts. Ensure area around injectors and intake
manifold is clean.
5) Using rocking motion, pull driver's side fuel rail with
injectors upward from intake manifold until injectors just clear
intake manifold. Repeat procedure on passenger's side fuel rail.
Remove fuel rails with injectors from intake manifold.
6) If removing injector from fuel rail, remove retaining clip
from fuel rail and injector. Retaining clip is located at top of
injector and fuel rail. Remove injector with "O" ring from fuel rail.
Installation
1) If installing injector on fuel rail, install NEW "O" ring
on injector. Coat "O" ring on injector with engine oil. Install
injector on fuel rail. Install retaining clip on injector and fuel
rail.
2) To install remaining components, reverse removal procedure
using NEW "O" ring at bottom of each injector. Coat "O" ring on
injector with engine oil before installing injectors and fuel rails.
3) Push passenger's side fuel rail and then driver's side
fuel rail downward until shoulder on each injector contacts the intake
manifold. Ensure all injectors are fully seated.
4) Tighten fuel rail bolts and throttle body bolts to
specification. See TORQUE SPECIFICATIONS. Install fuel line on fuel
rail using proper procedure. See FUEL LINE AT FUEL RAIL under FUEL
SYSTEM. Start engine and check for leaks.
Removal (Ram Pickup 8.0L)
1) Release fuel pressure from fuel system. See FUEL SYSTEM
PRESSURE RELEASE. Ensure negative battery cable is disconnected.
2) Remove throttle body from upper intake manifold. See
THROTTLE BODY. Remove ignition coils with mounting bracket for access
to fuel rails.
3) Upper intake manifold must be removed for servicing of
fuel rails and injectors. Remove generator-to-upper intake manifold
brace and A/C compressor-to-upper intake manifold brace. Remove
generator and A/C compressor if necessary for removal of upper intake
manifold.
4) Disconnect necessary vacuum lines and hoses for removal of
upper intake manifold. Remove bolts, upper intake manifold and gasket
from lower intake manifold.
5) Note electrical connector location on injectors for
installation reference. Disconnect electrical connectors at injectors.
Disconnect fuel line from fuel rail. See FUEL LINE AT FUEL RAIL.
6) Remove fuel rail bolts. Ensure area around injectors and
lower intake manifold is clean. Using rocking motion, pull driver's
side fuel rail with injectors upward from intake manifold until
injectors just clear intake manifold. Repeat procedure on passenger's
side fuel rail. Remove fuel rails with injectors from lower intake
manifold.
7) If removing injector from fuel rail, remove retaining clip
from fuel rail and injector. Retaining clip is located at top of
injector and fuel rail. Remove injector with "O" ring from fuel rail.

Removal (Dakota & Durango)
1) EVAP leak detection pump and EVAP leak detection pump
filter must be replaced as an assembly. EVAP leak detection pump is
located at driver's side of engine compartment, just below battery
tray. See Fig. 40. EVAP leak detection pump filter is attached to
outside of battery tray, just in front of power distribution center.
See Fig. 40 .
2) Remove battery. Disconnect hose from bottom of EVAP leak
detection pump filter that goes to EVAP leak detection pump. Remove
retaining clip and disconnect EVAP leak detection pump filter from
battery tray.
3) Disconnect wiring harness for battery temperature sensor
from bottom of battery tray. Power distribution center must be removed
for access to EVAP leak detection pump.
4) Remove power distribution center-to-fender retaining screw
at rear of power distribution center. Unsnap power distribution center
from battery tray. Carefully position power distribution center aside.
5) Remove battery tray. Disconnect electrical connector and
vacuum hoses at EVAP leak detection pump. Use care not to damage
vacuum hoses during removal. Remove retaining bolts and EVAP leak
detection pump.
NOTE: Vacuum hoses and hose to EVAP leak detection pump filter must
be properly installed on EVAP leak detection pump and all
hoses must be in good condition. If hoses are not properly
installed or are damaged, a Diagnostic Trouble Code (DTC)
will be set in the Powertrain Control Module (PCM).
Installation
1) Install EVAP leak detection pump on battery tray. Tighten
retaining bolts to specification. See TORQUE SPECIFICATIONS.
2) To install remaining components, reverse removal
procedure. Ensure vacuum hoses and hose to EVAP leak detection pump
filter are in good condition and properly installed on EVAP leak
detection pump.
Fig. 40: Locating EVAP Leak Detection Pump & EVAP Leak Detection
Pump Filter (Dakota & Durango)

or damage.
* Once a month, Inspect battery and clean and tighten
terminals as required.
* Once a month, check fluid levels of coolant reservoir,
brake master cylinder, power steering & transmission.
Add fluids as required.
* Once a month, check all lights and all other electrical items
for correct operation
* Once a month, Inspect and clean wiper blades as required.
* Twice a year, lubricate the external lock cylinders.

  Model 248 (4WD)  7.3 Pts. (3.4L) 


\
\
\

\
\


 Model 267 (2WD)  7 Pts. (3.3L) 


\
\
\

\
\


 Model 267 (4WD)  7.8 Pts. (3.6L) 


\
\
\

\
\


 Model 286 (2WD)  6.8.Pts. (3.2L) 


\
\
\

\
\


 Model 286 (4WD)  10.1 Pts. (4.8L) 

\

\
\
\

\
\
\


Rear Axle  Model 248 (2WD)  6.3 Pts. (3L) 

Limited Slip 
\
\
\

\
\


Differential  Model 248 (4WD)  7.3 Pts. (3.4L) 


\
\
\

\
\


 Model 267 (2WD)  7 Pts. (3.3L) 


\
\
\

\
\


 Model 267 (4WD)  7.8 Pts. (3.6L) 


\
\
\

\
\


 Model 286 (2WD)  6.8 Pts. (3.2L) 


\
\
\

\
\


 Model 286 (4WD)  10.1 Pts. (4.8L) 

\

\
\
\

\
\
\


Front Axle  Model 216  6.8 Pts. (3.6L) 

Lubricant 
\
\
\

\
\


 Model 248  7.6 Pts. (3.6L) 

\

\
\
\

\
\
\


Transfer Case NV231 HD  2.5 Pts. (1.2L) 

Fluid   

\

\
\
\

\
\
\


Power Take  NV021  4.6 Pts. (2.1L) 

Off Adapter   

\

\
\
\

\
\
\


Power  Drained  2.7 Pts. (1.3L) 

Steering   

Fluid   

\

\
\
\

\
\
\


A/C  Charge Capacity  32 Oz. (.9Kg) 

Refrigerant   

  

\

\
\
\

\
\
\


Refrigerant  A/C System Capacity  7.75 Oz. (230ML) 

Oil   

\

\
\
\

\
\
\


Fuel Tank 119" & 139" Wheelbase Vehicles 26 Gal. (98L) 


\
\
\

\
\


 All Others  35 Gal. (132L) 

\
\
\
\
\
\
\


(
1) - Capacities are recommended or calculated levels. Always use 

dipstick (if available) to measure level. 
\f
\
\
\
\
\
\
\


MISCELLANEOUS NOTES
* Once a month, check tire pressure and look for unusual wear
or damage.
* Once a month, Inspect battery and clean and tighten
terminals as required.
* Once a month, check fluid levels of coolant reservoir,
brake master cylinder, power steering & transmission.
Add fluids as required.
* Once a month, check all lights and all other electrical items
for correct operation

 Lubricant   

\

\
\
\

\
\
\


Transfer Case NV241 HD  6.5 Pts. (3.1L) 

Fluid   

\

\
\
\

\
\
\


Power Take  NV021  4.6 Pts. (2.1L) 

Off Adapter   

\

\
\
\

\
\
\


Power  Drained  2.7 Pts. (1.3L) 

Steering   

Fluid   

\

\
\
\

\
\
\


A/C  Charge Capacity  32 Oz. (.9Kg) 

Refrigerant   

  

\

\
\
\

\
\
\


Refrigerant  A/C System Capacity  7.75 Oz. (230ML) 

Oil   

\

\
\
\

\
\
\


Fuel Tank  Capacity  35 Gal. (132L) 

\
\
\
\
\
\
\




(
1) - Capacities are recommended or calculated levels. Always use 

dipstick (if available) to measure level. 
\f
\
\
\
\
\
\
\


MISCELLANEOUS NOTES
* Once a month, check tire pressure and look for unusual wear
or damage.
* Once a month, inspect battery and clean and tighten
terminals as required.
* Once a month, check fluid levels of coolant reservoir,
brake master cylinder, power steering & transmission.
Add fluids as required.
* Once a month, check all lights and all other electrical items
for correct operation
* Once a month, drain water from fuel filter.
* Once a month, check Filter Minder.
* Once a month, inspect and clean wiper blades as required.

 \
\
\

\
\


 Model 286 (4WD)  10.1 Pts. (4.8L) 

\

\
\
\

\
\
\


Rear Axle  Model 248 (2WD)  6.3 Pts. (3L) 

Limited Slip 
\
\
\

\
\


Differential  Model 248 (4WD)  7.3 Pts. (3.4L) 


\
\
\

\
\


 Model 267 (2WD)  7 Pts. (3.3L) 


\
\
\

\
\


 Model 267 (4WD)  7.8 Pts. (3.6L) 


\
\
\

\
\


 Model 286 (2WD)  6.8 Pts. (3.2L) 


\
\
\

\
\


 Model 286 (4WD)  10.1 Pts. (4.8L) 

\

\
\
\

\
\
\


Front Axle  Model 216  6.8 Pts. (3.6L) 

Lubricant 
\
\
\

\
\


 Model 248  7.6 Pts. (3.6L) 

\

\
\
\

\
\
\


Transfer Case NV241  5 Pts. (2.7L) 

Fluid 
\
\
\

\
\


 NV241 HD  6.5 Pts. (3.5L) 


\
\
\

\
\


 NV241 HD W/PTO  9 Pts. (4.9L) 

\

\
\
\

\
\
\


Power Take  NV021  4.6 Pts. (2.1L) 

Off Adapter   

\

\
\
\

\
\
\


Power  Drained  2.7 Pts. (1.3L) 

Steering   

Fluid   

\

\
\
\

\
\
\


A/C  Charge Capacity  32 Oz. (.9Kg) 

Refrigerant   

  

\

\
\
\

\
\
\


Refrigerant  A/C System Capacity  7.75 Oz. (230ML) 

Oil   

\

\
\
\

\
\
\


Fuel Tank 119" & 139" Wheelbase Vehicles 26 Gal. (98L) 


\
\
\

\
\


 All Others  35 Gal. (132L) 

\
\
\
\
\
\
\


(
1) - Capacities are recommended or calculated levels. Always use 

dipstick (if available) to measure level. 
\f
\
\
\
\
\
\
\


MISCELLANEOUS NOTES
* Once a month, check tire pressure and look for unusual wear
or damage.
* Once a month, Inspect battery and clean and tighten
terminals as required.
* Once a month, check fluid levels of coolant reservoir,
brake master cylinder, power steering & transmission.
Add fluids as required.
* Once a month, check all lights and all other electrical items
for correct operation
* Once a month, Inspect and clean wiper blades as required.
* Twice a year, lubricate the external lock cylinders.


C - S PEC IF IC ATIO NS

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Service & Adjustment Specifications - Trucks
Caravan, Dakota, Durango, Ram Pickup, Ram Van, Ram Wagon,
Town & Country, Voyager
INTRODUCTION
Use this article to quickly find specifications related to
servicing and on-vehicle adjustments. This is a quick-reference
article to use when you are familiar with an adjustment procedure and
only need a specification.
CAPACITIES
BATTERY SPECIFICATIONS








\









\









\









\









\









\









\







Application & Group Cold Cranking Amp Hr.
Amps Rating
Caravan
2.4L (Group 34) ....................... 600 ................. 66\
3.0L (Group 34) ....................... 500 ................. 60\
3.3L (Group 34) ....................... 500 ................. 60\
3.8L
Std. Battery (Group 34) .............. 600 ................. 66\
Opt. Battery (Group 34) .............. 685 ................. 72\
Dakota & Durango
Std. Battery (Group 27) ............... 600 ................. 66\
Opt. Battery (Group 27) ............... 750 ................. 75\
Ram Pickup
3.9L, 5.2L & 5.9L (Gasoline)
Std. Battery (Group 27) .............. 600 ................. 66\
Opt. Battery (Group 27) .............. 750 ................. 75\
5.9L (Diesel) ( 2) & 8.0L .............. 750 ................. 75
Ram Van & Ram Wagon
Std. Battery (Group 27) ............... 600 ................. 66\
Opt. Battery (Group 27) ............... 750 ................. 75\
Town & Country
3.3L (Group 34) ....................... 500 ................. 60\
3.8L
Std. Battery (Group 34) .............. 600 ................. 66\
Opt. Battery (Group 34) .............. 685 ................. 72\
Voyager
2.4L (Group 34) ....................... 600 ................. 66\
3.0L (Group 34) ....................... 500 ................. 60\
3.3L (Group 34) ....................... 500 ................. 60\
( 1) - Information is not available from manufacturer.
( 2) - Two batteries.









\









\









\









\









\









\









\







FLUID CAPACITIES (CARAVAN, TOWN & COUNTRY, & VOYAGER)








\









\









\









\









\









\









\







Application ( 1) Quantity
Crankcase (Includes Filter) ( 2)
2.4L, 3.0L, 3.3L & 3.8L .......................... 4.5 Qts. (4.3L)\
Cooling System ( 3)

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.









\









\









\









\









\









\









\







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









\









\









\









\









\









\









\







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