ignition 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 1170 of 1691
SC HED ULE D S ER VIC ES
INSPECT
Exhaust System
Brake Hoses
Engine Coolant Level, Hoses & Clamps
Engine Air Cleaner & Air Pump Filters
Brake Linings
SERVICE
Lubricate Steering Linkage
Automatic Transmission Bands
Clean EGR Passages (5.9L)
REPLACE
Engine Oil
Engine Oil Filter (
1)
Automatic Transmission Fluid & Filter
Rear Axle Fluid
Front Axle Fluid (4x4)
Spark Plugs
Ignition Cables
PCV Valve (5.9L)
EGR Valve (5.9L)
Distributor Cap & Rotor (5.9L)
(
1) 8.0L: Change oil filter at every oil change.
5.9L: If mileage is less than 6,000 miles (9,600 Km) Yearly,
replace the oil filter at every oil change.
LUBRICATION SPECIFICATIONS
Material Condition Specification
Engine Oil Ambient Temperature Above 0 F SAE 10W-30
(
1) (-18 C) To Over 100 F (38 C)
Ambient Temperature Less Than SAE 5W-30
-20 F (-29 C) Up To 32 F (0 C)
Engine All 50/50 Mixture Of
Coolant Distilled Water &
Ethylene Glycol
Brake Fluid All DOT 3
Page 1189 of 1691
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.
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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
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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
Page 1190 of 1691
2.4L ............................. 170-225 psi (11.9-15.7 kg/cm)
3.0L ...................................... 178 psi (12.5 kg/cm)
3.3L ........................................................ ( 1)
Minimum Compression Pressure
Caravan, Town & Country, & Voyager .......... 100 psi (7.0 kg/cm
)
Dakota
2.5L ........................................................ ( 1)
3.9L, 5.2L & 5.9L .......................... 100 psi (7.0 kg/cm
)
Durango ..................................... 100 psi (7.0 kg/cm)
Ram Pickup
3.9L, 5.2L & 5.9L (Gasoline) & 8.0L ........ 100 psi (7.0 kg/cm
)
5.9L (Diesel) ............................................... ( 1)
Ram Van & Ram Wagon ......................... 100 psi (7.0 kg/cm
)
Maximum Variation Between Cylinders
Caravan, Town & Country & Voyager ..................... 25 Percent
Dakota
2.5L ........................................ 30 psi (2.1 kg/cm
)
3.9L, 5.2L & 5.9L ........................................... ( 1)
Durango ...................................................... ( 1)
Ram Pickup, Ram Van & Ram Wagon .............................. ( 1)
( 1) - Information is not available from manufacturer.
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VALVE CLEARANCE
Gasoline Models
All engines are equipped with hydraulic lifters. No
adjustments are required.
5.9L Diesel (Ram Pickup)
Valve adjustment is recommended every 150 months or 150,000
miles during normal service, every 135,000 miles during severe
service. Severe service is described as frequent short trip operation
of less than 5 miles, long periods of engine idling, trailer towing,
police, taxi, local delivery service, or operating in dusty or
excessively hot conditions. See VALVE CLEARANCE SPECIFICATIONS
(DIESEL) table.
VALVE CLEARANCE SPECIFICATIONS (DIESEL) ( 1)
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Application In. (mm)\
Intake Valve ............................................ .010 (.25)\
Exhaust Valve ........................................... .020 (.51)\
(1) - Adjust valves with engine temperature less than 140
F (60C). \
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IGNITION SYSTEM
IGNITION COIL
IGNITION COIL RESISTANCE - Ohms @ 70-80F (21-27C) \
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Application Primary Secondary
Caravan
2.4L
Diamond ( 1)( 2) ............... .53-.65 .......... 11,500-13,500
Weastec ( 1) .................. .45-.65 .......... 10,900-14,700
3.0L ............................. ( 3) ..................... ( 3)
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3.3L & 3.8L ................... .45-.65 ............ 7000-15,800
Dakota & Durango
Diamond (1)( 2) ................ .97-1.18 ......... 11,300-15,300
Toyodenso ( 1) ................. .95-1.20 ......... 11,300-13,300
Ram Pickup
Except 8.0L
Diamond ( 1)( 2) ............... .97-1.18 ......... 11,300-15,300
Toyodenso ( 1) ................ .95-1.20 ......... 11,300-13,300
8.0L .......................... .53-.65 .......... 10,900-14,700
Ram Van & Ram Wagon
Diamond ( 1)( 2) ................ .97-1.18 ......... 11,300-15,300
Toyodenso ( 1) ................. .95-1.20 ......... 11,300-13,300
Town & Country .................. .45-.65 ............ 7000-15,800
Voyager
2.4L
Diamond ( 1)( 2) ............... .53-.65 .......... 11,500-13,500
Weastec ( 1) .................. .45-.65 .......... 10,900-14,700
3.0L ............................ ( 3) ...................... ( 3)
3.3L .......................... .45-.65 ............ 7000-15,800
( 1) - This is the manufacturer of ignition coil.
( 2) - Brass terminals.
( 3) - Information is not available from manufacturer.
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HIGH TENSION WIRE RESISTANCE
HIGH TENSION WIRE RESISTANCE \
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Application Ohms
Caravan ( 1)
2.4L
Cylinder No. 1 Or 4 ........................................ 4200
Cylinder No. 2 Or 3 ........................................ 3200
3.0L
Cylinder No. 1 ........................................... 14,000
Cylinder No. 2 ........................................... 10,400
Cylinder No. 3 ........................................... 14,900
Cylinder No. 4 ........................................... 11,500
Cylinder No. 5 ........................................... 17,500
Cylinder No. 6 ........................................... 10,300
Ignition Coil Wire ....................................... 11,100
3.3L & 3.8L
Cylinder No. 1 ........................................... 18,500
Cylinder No. 2 ........................................... 15,500
Cylinder No. 3 ........................................... 20,400
Cylinder No. 4 ........................................... 21,200
Cylinder No. 5 ........................................... 27,700
Cylinder No. 6 ........................................... 26,700
Dakota & Durango
All High Tension Wires ....................................... ( 2)
Ram Pickup, Ram Van & Ram Wagon
All High Tension Wires ....................................... ( 2)
Town & Country ( 1)
Cylinder No. 1 ............................................ 18,500
Cylinder No. 2 ............................................ 15,500
Cylinder No. 3 ............................................ 20,400
Cylinder No. 4 ............................................ 21,200
Cylinder No. 5 ............................................ 27,700
Cylinder No. 6 ............................................ 26,700
Voyager ( 1)
2.4L
Page 1192 of 1691
Cylinder No. 1 Or 4 ........................................ 4200
Cylinder No. 2 Or 3 ........................................ 3200
3.0L
Cylinder No. 1 ........................................... 14,000
Cylinder No. 2 ........................................... 10,400
Cylinder No. 3 ........................................... 14,900
Cylinder No. 4 ........................................... 11,500
Cylinder No. 5 ........................................... 17,500
Cylinder No. 6 ........................................... 10,300
Ignition Coil Wire ....................................... 11,100
3.3L
Cylinder No. 1 ........................................... 18,500
Cylinder No. 2 ........................................... 15,500
Cylinder No. 3 ........................................... 20,400
Cylinder No. 4 ........................................... 21,200
Cylinder No. 5 ........................................... 27,700
Cylinder No. 6 ........................................... 26,700
(1) - Maximum wire resistance is listed according to high tension wire
application. For cylinder identification, see FIRING ORDER &
TIMING MARKS.
( 2) - Resistance should be 250-1000 ohms per one inch or 3000-12,000
ohms per 12 inches.
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SPARK PLUGS
SPARK PLUG TYPE ( 1) \
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Application Champion No.
Caravan
2.4L ..................................................... RC12YC5
3.0L ..................................................... RN11YC4
3.3L & 3.8L ............................................. RN14PMP5
Dakota
2.5L ..................................................... RC12ECC
3.9L, 5.2L & 5.9L ........................................ RC12LC4
Durango .................................................... RC12LC4
Ram Pickup
3.9L, 5.2L & 5.9L ........................................ RC12LC4
8.0L ...................................................... QC9MC4
Ram Van & Ram Wagon ........................................ RC12LC4
Town & Country ............................................ RN14PMP5
Voyager
2.4L ..................................................... RC12YC5
3.0L ..................................................... RN11YC4
3.3L .................................................... RN14PMP5
(1) - Check spark plug application on underhood vehicle emission
control label. If application differs from application listed,
use application on underhood vehicle emission control label.
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SPARK PLUG SPECIFICATIONS ( 1) \
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Application Gap Torque
In. (mm) Ft. Lbs. (N.m\
)
Caravan
2.4L ................ .048-.053 (1.22-1.35) ............ 20 (27\
)
3.0L ................ .039-.044 (1.00-1.12) ............ 20 (27\
)
3.3L & 3.8L ......... .048-.053 (1.22-1.35) ............ 20 (27\
)
Page 1198 of 1691
Fig. 8: Firing Order 8.0L V10 (Ram Pickup)
IGNITION TIMING
NOTE: On all models, ignition timing is controlled by Powertrain
Control Module (PCM). Ignition timing is non-adjustable. DO
NOT attempt to adjust ignition timing.
NOTE: On Dakota 3.9L, 5.2L and 5.9L, Durango, Ram Pickup 3.9L, 5.2L
and 5.9L (gasoline), Ram Van and Ram Wagon, the distributor
can be checked for proper location. See FUEL SYSTEM
SYNCHRONIZATION under FUEL SYSTEM in ON-VEHICLE ADJUSTMENTS.
FUEL SYSTEM
FUEL PUMP (GASOLINE)
FUEL PUMP PERFORMANCE \
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Application Pressure psi Min. Vol.
(kg/cm) In 7 Sec. Pts. (L)
Page 1199 of 1691
Caravan
2.4L & 3.0L ............ (2) 43-53 (3.0-3.7) ............... ( 3)
3.3L
Flex-Fuel ............. ( 2) 50-60 (3.5-4.2) ............... ( 3)
Except Flex-Fuel ...... ( 2) 43-53 (3.0-3.7) ............... ( 3)
3.8L ................... ( 2) 43-53 (3.0-3.7) ............... ( 3)
Dakota & Durango ......... ( 1) 44-54 (3.0-3.8) ........... .5 (24)
Ram Pickup, Ram Van
& Ram Wagon ............. ( 1) 44-54 (3.0-3.8) ........... .5 (24)
Town & Country
3.3L
Flex-Fuel ............. ( 2) 50-60 (3.5-4.2) ............... ( 3)
Except Flex-Fuel ...... ( 2) 43-53 (3.0-3.7) ............... ( 3)
3.8L ................... ( 2) 43-53 (3.0-3.7) ............... ( 3)
Voyager
2.4L & 3.0L ............ ( 2) 43-53 (3.0-3.7) ............... ( 3)
3.3L
Flex-Fuel ............. ( 2) 50-60 (3.5-4.2) ............... ( 3)
Except Flex-Fuel ...... ( 2) 43-53 (3.0-3.7) ............... ( 3)
( 1) - Manufacturer lists fuel pressure with engine idling.
( 2) - Manufacturer lists fuel pressure with engine off, ignition on
and using scan tool to activate fuel pump.
( 3) - Information is not available from manufacturer.
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FUEL INJECTION PUMP & FUEL TRANSFER PUMP (DIESEL)
NOTE: For fuel injection pump timing, see appropriate ON-VEHICLE
ADJUSTMENTS article.
FUEL INJECTION PUMP PERFORMANCE (DIESEL)
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Application Output Pressure psi (kg/cm)
Ram Pickup 5.9L ................................................ ( 1)
( 1) - Pressure testing procedure and output pressure is not available
from manufacturer.
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NOTE: For testing of fuel transfer pump, see appropriate BASIC
DIAGNOSTIC PROCEDURES article.
INJECTOR OPENING PRESSURE (DIESEL)
INJECTOR OPENING PRESSURE (DIESEL) \
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Application psi (kg/cm)
Ram Pickup 5.9L ......................................... 4500 (316)\
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INJECTOR RESISTANCE
INJECTOR RESISTANCE \
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Application Ohms @ 68F (20C)
All Models ................................................... 10-16
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Page 1201 of 1691
![DODGE RAM 1999 Service Repair Manual THROTTLE POSITION SENSOR VOLTAGE SPECIFICATIONS \
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\](/img/12/56915/w960_56915-1200.png "DODGE RAM 1999 Service Repair Manual THROTTLE POSITION SENSOR VOLTAGE SPECIFICATIONS \
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THROTTLE POSITION SENSOR VOLTAGE SPECIFICATIONS \
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Throttle Opening Volts
Caravan, Town & Country, & Voyager (1)( 2)
At Idle ................................................. .38-1.20
At Full Throttle ....................................... 3.10-4.40
Dakota & Durango ( 1)( 2)
At Idle .................................................. .26-.90
At Full Throttle .................................. Less Than 4.50
Ram Pickup ( 1)( 2)
3.9L, 5.2L, 5.9L (Gasoline) & 8.0L ( 1)( 2)
At Idle ................................................. .35-.90
At Full Throttle ................................. Less Than 4.50
5.9L (Diesel) ................................................ ( 3)
Ram Van & Ram Wagon ( 1)( 2)
At Idle .................................................. .35-.90
At Full Throttle .................................. Less Than 4.50
( 1) - Measure voltage at center terminal on throttle position sensor
with ignition on.
( 2) - Voltage should increase smoothly when moving throttle from idle
to full throttle.
( 3) - Diesel Accelerator Pedal Position Sensor (APPS) is not
adjustable. Voltage should be less than one volt at idle and
more than 3 volts at full throttle.
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Page 1209 of 1691
STA R TE R
1999 D odge P ic ku p R 1500
1999 STARTING & CHARGING SYSTEMS
CHRY - Starters - Except Avenger & Sebring Coupe
Breeze, Caravan, Cirrus, Concorde, Dakota, Durango, Intrepid,
LHS, Neon, Ram Pickup, Ram Van, Ram Wagon, Sebring
Convertible, Stratus, Town & Country, Voyager, 300M
NOTE: For models not covered in this article, see STARTERS -
AVENGER, SEBRING COUPE & TALON article.
DESCRIPTION
Bosch, Melco and Mitsubishi starters use a planetary gear
train that transmits power from starter motor to pinion shaft. Six
permanent magnets (Bosch and Melco starters) or 4 permanent magnets
(Mitsubishi starters) are used, eliminating potential field wire-to-
frame short circuits.
Nippondenso starter is a 4-field, 4-brush, 12-volt motor with
a solenoid mounted within the housing. The unit has a 2-to-1 reduction
gear set in a die cast aluminum housing. Starter has serviceable gear
and clutch assembly only. If starter solenoid fails, entire starter
motor must be replaced.
All models use a starter relay in starter circuit between the
battery and starter solenoid terminal. Automatic Transmission (A/T)
equipped vehicles use a Park/Neutral Position (PNP) switch or a
Transmission Range (TR) sensor to provide ground path for the starter
relay. Manual Transmission (M/T) equipped vehicles use a clutch pedal
position switch to provide battery voltage from ignition switch to the
starter relay. See WIRING DIAGRAMS.
STARTER APPLICATIONS - CARS
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Model Type
Breeze & Stratus 2.0L ........................................ Bosch
Cirrus, Sebring Convertible & Stratus
2.4L ................................................. Nippondenso
2.5L ....................................................... Melco
Concorde, Intrepid, LHS & 300M
2.7L ....................................................... Melco
3.3L & 3.5L .......................................... Nippondenso
Neon ......................................................... Bosch
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STARTER APPLICATIONS - TRUCKS \
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Model Type
Caravan, Town & Country, & Voyager ..................... Nippondenso
Dakota & Durango
2.5L .................................................. Mitsubishi
3.9L & 5.2L .......................................... Nippondenso
Ram Pickup, Ram Van & Ram Wagon ........................ Nippondenso
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TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION.
Page 1210 of 1691
ON-VEHICLE TESTING
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.
DISABLING/ENABLING IGNITION & FUEL SYSTEMS
WARNING: To prevent engine from starting while performing tests,
always disable ignition and fuel systems.
Disabling Ignition & Fuel Systems
Remove Automatic Shutdown Relay (ASD) located in Power
Distribution Center (PDC). Refer to PDC cover for proper relay
location. PDC is located in engine compartment. On 5.9L diesel
engines, also disconnect fuel shutdown solenoid connector. Solenoid is
located behind upper intake manifold. See appropriate SYSTEM &
COMPONENT TESTING article in ENGINE PERFORMANCE section.
Enabling Ignition & Fuel Systems
When testing and/or repairs have been completed, verify
battery condition. Recharge battery as necessary, after starter tests
have been completed. Disconnect all test equipment. Install ASD relay.
On 5.9L diesel engines, reconnect fuel shutdown relay connector. On
all models, start engine several times to verify malfunction has been
corrected.
CRANKING TEST
NOTE: Ensure engine is at normal operating temperature. High
viscosity oil, extreme cold temperatures, or tight engine
will increase amperage draw.
1) Using a battery load tester, connect positive and negative
leads to battery. Connect inductive ammeter pick-up to positive
battery cable. Disable ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS.
2) Ensure all lights and accessories are off. Place A/T in
Park position or M/T in Neutral position. Apply parking brake. Crank
engine and observe voltmeter reading. If voltage is more than 9.6
volts and cranking amperage draw is more than specified amps, proceed
to CIRCUIT RESISTANCE TESTS. See STARTER SPECIFICATIONS - CARS or
STARTER SPECIFICATIONS - TRUCKS.
3) If voltage is 12.5 volts or more and cranking amperage
draw is less than specified, check starter circuit components in the
following order:
starter solenoid, starter relay, starter relay circuit, park/neutral
position switch or transmission range sensor (A/T), clutch pedal
position switch (M/T), ignition switch, wiring harness and
connections.
CIRCUIT RESISTANCE TESTS
NOTE: If excessive resistance is not found in circuits being
tested, remove starter and proceed to BENCH TESTING.
Battery Connection Resistance Test
1) Disable vehicle ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS. A voltmeter accurate to
one tenth of a volt will be needed for the following tests.