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 613 of 1691
Spark control systems are designed to ensure the air/fuel
mixture is ignited at the best possible moment to provide optimum
efficiency and power and cleaner emissions.
Ensure vacuum hoses to the distributor, carburetor, spark
delay valves, thermal vacuum switches, etc., are in place and routed
properly. On Computerized Engine Controls (CEC), check for presence of\
required sensors (O2, MAP, CTS, TPS, etc.). Ensure they have not been
tampered with or modified.
Check for visible modification or replacement of the feedback
carburetor, fuel injection unit or injector(s) with a non-feedback
carburetor or fuel injection system. Check for modified emission-
related components unacceptable for use on pollution-controlled
vehicles.
AIR INJECTION SYSTEM (AIS)
Air Pump Injection System (AP)
The air pump is a belt-driven vane type pump, mounted to
engine in combination with other accessories. The air pump itself
consists of the pump housing, an inner air cavity, a rotor and a vane
assembly. As the vanes turn in the housing, filtered air is drawn in
through the intake port and pushed out through the exhaust port. See
Fig. 13 .
Check for missing or disconnected belt, check valve(s),
diverter valve(s), air distribution manifolds, etc. Check air
injection system for proper hose routing.
Fig. 13: Typical Air Pump Injection System
Courtesy of General Motors Corp.
Pulsed Secondary Air Injection (PAIR) System
PAIR eliminates the need for an air pump and most of the
associated hardware. Most systems consists of air delivery pipe(s),
pulse valve(s) and check valve(s). The check valve prevents exhaust
gases from entering the air injection system. See Fig. 14.
Ensure required check valve(s), diverter valve(s), air
distribution manifolds, etc., are present. Check air injection system
for proper hose routing.
Page 614 of 1691
Fig. 14: Typical Pulsed Secondary Air Injection System
Courtesy of General Motors Corp.
OXYGEN SENSOR (O2)
The O2 sensor is mounted in the exhaust system where it
monitors oxygen content of exhaust gases. Some vehicles may use 2 O2
sensors. The O2 sensor produces a voltage signal which is proportional
to exhaust gas oxygen concentration (0-3%) compared to outside oxygen
(20-21%). This voltage signal is low (about .1 volt) when a lean
mixture is present and high (1.0 volt) when a rich mixture is present.\
As ECM compensates for a lean or rich condition, this voltage
signal constantly fluctuates between high and low, crossing a
reference voltage supplied by the ECM on the O2 signal line. This is
referred to as cross counts. A problem in the O2 sensor circuit should
set a related trouble code.
COMPUTERIZED ENGINE CONTROLS (CEC)
The CEC system monitors and controls a variety of
engine/vehicle functions. The CEC system is primarily an emission
control system designed to maintain a 14.7:1 air/fuel ratio under most
operating conditions. When the ideal air/fuel ratio is maintained, the
catalytic converter can control oxides of nitrogen (NOx), hydrocarbon
(HC) and carbon monoxide (CO) emissions.
The CEC system consists of the following sub-systems:
Electronic Control Module (ECM), input devices (sensors and switches)\
and output signals.
Page 615 of 1691
EARLY FUEL EVAPORATION (EFE)
The EFE valve is actuated by either a vacuum actuator or a
bimetal spring (heat-riser type). The EFE valve is closed when engine
is cold. The closed valve restricts exhaust gas flow from the exhaust
manifold. This forces part of the exhaust gas to flow up through a
passage below the carburetor. As the exhaust gas quickly warms the
intake mixture, distribution is improved. This results in better cold
engine driveability, shorter choke periods and lower emissions.
Ensure EFE valve in exhaust manifold is not frozen or rusted
in a fixed position. On vacuum-actuated EFE system, check EFE thermal
vacuum valve and check valve(s). Also check for proper vacuum hose
routing. See Fig. 15.
Fig. 15: Typical Vacuum-Actuated EFE System
Courtesy of General Motors Corp.
EMISSION MAINTENANCE REMINDER LIGHT (EMR) (IF EQUIPPED)
Page 616 of 1691
If equipped, the EMR light (some models may use a reminder
flag) reminds vehicle operator that an emission system maintenance is
required. This indicator is activated after a predetermined
time/mileage.
When performing a smog check inspection, ensure EMR indicator
is not activated. On models using an EMR light, light should glow when
ignition switch is turned to ON position and should turn off when
engine is running.
If an EMR flag is present or an EMR light stays on with
engine running, fail vehicle and service or replace applicable
emission-related components. To reset an EMR indicator, refer to
appropriate MAINTENANCE REMINDER LIGHTS in the MAINTENANCE section.
MALFUNCTION INDICATOR LIGHT (MIL)
The Malfunction Indicator Light (MIL) is used to alert
vehicle operator that the computerized engine control system has
detected a malfunction (when it stays on all the time with engine
running). On some models, the MIL may also be used to display trouble
codes.
As a bulb and system check, malfunction indicator light will
glow when ignition switch is turned to ON position and engine is not
running. When engine is started, light should go out.
Page 617 of 1691
EN G IN E C O OLIN G S PEC IF IC ATIO NS
1999 D odge P ic ku p R 1500
1998-99 ENGINE COOLING
CHRY - Specifications - All Models
1998 Talon
1998-99 Avenger, Breeze, Caravan, Cirrus, Concorde, Dakota,
Durango, Intrepid, Neon, Ram Pickup, Ram Van/Wagon, Sebring
Convertible, Sebring Coupe, Stratus, Town & Country, Voyager
1999 LHS, 300M
BELT ADJUSTMENT
NOTE: For belt routing on models not covered in this article,
information was not available. See underhood label for proper
belt routing.
Belts should be adjusted to proper tension using belt tension
gauge. See appropriate BELT ADJUSTMENT SPECIFICATIONS table. Some
models may be equipped with an automatic belt tensioner. Ensure
serpentine belts are routed properly. See Figs. 5 through 14.
4-CYLINDER BELT ADJUSTMENT SPECIFICATIONS - CARS
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Application New Belt (1) Used Belt
Lbs. (kg) Lbs. (kg\
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Avenger & Sebring Coupe
2.0L
Generator ................... 110-160 (50-73) .. 90-110 (41-50\
)
Power Steering
With A/C .................. 137-159 (62-72) .. 93-115 (42-52\
)
Without A/C ............... 110-160 (50-73) .. 90-110 (41-50\
)
Breeze, Cirrus & Stratus
2.0L & 2.4L
A/C & Generator .................. 150 (68) ............ 80 (36\
)
Power Steering .................. 130 (59) ............ 80 (36\
)
Neon
2.0L (DOHC & SOHC)
A/C & Pwr. Steering ............. 135 (61) ........... 100 (45\
)
Generator ....................... 135 (61) ........... 100 (45\
)
Sebring Convertible
2.4L .......................... 150 (68) ............ 80 (36\
)
Talon
2.0L Non-Turbo
Generator ................... 110-160 (50-73) .. 90-110 (41-50\
)
Power Steering
With A/C .................. 137-159 (62-72) .. 93-115 (42-52\
)
Without A/C ............... 110-160 (50-73) .. 90-110 (41-50\
)
2.0L Turbo
A/C ........................... 86-99 (39-45) ... 57-75 (26-34\
)
Generator ..................... 110-154 (50-70) ........ 88 (40\
)
Power Steering ............... 110-154 (50-70) .. 77-92 (35-42\
)
( 1) - Belt is considered used after 15 minutes of service.
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V6 BELT ADJUSTMENT SPECIFICATIONS - CARS \
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Application New Belt (1) Used Belt
Lbs. (kg) Lbs. (kg\
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Page 618 of 1691
![DODGE RAM 1999 Service Repair Manual Avenger & Sebring Coupe
2.5L
A/C ......................... 110-132 (50-60) ... 66-86 (30-39\
)
Generator & P/S ............. 143-187 (65-85) .. 99-121 (45-55\
)
Cirrus & Stratus 2.5L](/img/12/56915/w960_56915-617.png "DODGE RAM 1999 Service Repair Manual Avenger & Sebring Coupe
2.5L
A/C ......................... 110-132 (50-60) ... 66-86 (30-39\
)
Generator & P/S ............. 143-187 (65-85) .. 99-121 (45-55\
)
Cirrus & Stratus 2.5L")
Avenger & Sebring Coupe
2.5L
A/C ......................... 110-132 (50-60) ... 66-86 (30-39\
)
Generator & P/S ............. 143-187 (65-85) .. 99-121 (45-55\
)
Cirrus & Stratus 2.5L
A/C & Generator ................. 150 (68) ............. 80 (36\
)
Power Steering .................. 130 (59) ............. 80 (36\
)
Concorde, Intrepid, LHS & 300M
2.7L
All Belts ................... 180-200 (78-91) ........ 120 (54\
)
3.2L & 3.5L
A/C ......................... 140-160 (64-73) ........ 120 (54\
)
Generator & Power Steering ..... 180-200 (78-91) ........ 120 (54\
)
Sebring Convertible
2.5L .......................... 150 (68) ............ 80 (36\
)
(1) - Belt is considered used after 15 minutes of service.
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BELT ADJUSTMENT SPECIFICATIONS - TRUCKS \
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Application New Belt (1) Used Belt
Lbs. (kg) Lbs. (kg\
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Dakota & Durango
2.5L ........................ 180-200 (82-91) .. 140-160 (64-73\
)
3.9L, 5.2L & 5.9L ................. ( 2) .................... ( 2)
FWD Vans
Caravan & 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 & P/S ................ ( 2) .................... ( 2)
3.3L & 3.8L ...................... ( 2) .................... ( 2)
Town & Country
3.3L & 3.8L ...................... ( 2) .................... ( 2)
Ram Pickup & Ram Van/Wagon
All Engines ....................... ( 2) .................... ( 2)
( 1) - Belt is considered used after 15 minutes of service.
( 2) - Automatic belt tensioner is used. Belt tension adjustment is not
required.
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Fig. 1: Belt Routing (2.0L Avenger, Sebring Coupe & Talon Without
Turbo)
Courtesy of Chrysler Corp.
Page 627 of 1691
COOLING SYSTEM BLEEDING
GASOLINE ENGINES
Air in system will collect under radiator cap. As engine
reaches operating temperature, coolant and any trapped air will enter
reserve tank. As engine cools, a vacuum will be created which will
draw only coolant into cooling system. After engine has gone through a
warm-up and cooling cycle, run engine until it again reaches operating
temperature. Ensure coolant in reserve tank is at warm coolant mark on
reserve tank or dipstick.
5.9L DIESEL ENGINE
For bleeding procedures on 5.9L diesel, see appropriate 12-
valve or 24-valve engine article in ENGINES. DO NOT operate engine
while filling cooling system.
SPECIFICATIONS
COOLING SYSTEM SPECIFICATIONS
COOLING SYSTEM SPECIFICATIONS - CARS \
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Application Specification
Avenger & Sebring Coupe
Coolant Replacement Interval ........... 30,000 Miles Or 24 Months
Coolant Capacity ................................. 7.4 Qts. (7.0L)\
Pressure Cap .............................................. 16 psi
Thermostat
DOHC
Starts To Open ................................... 195
F (91C)
Fully Opens ..................................... 216F (102C)
SOHC
Starts To Open ................................... 180
F (82C)
Fully Opens ...................................... 203F (95C)
Breeze, Cirrus, Sebring Convertible & Stratus
Coolant Replacement Interval ........... 45,000 Miles Or 36 Months
Coolant Capacity
2.0L ............................................ 8.5 Qts. (8.0L)\
2.4L ............................................ 9.0 Qts. (8.5L)\
2.5L .......................................... 10.5 Qts. (10.0L)\
Pressure Cap ........................................... 14-18 psi
Thermostat
Starts To Open .............................. 192-199
F (88-93C)
Fully Opens ....................................... 220F (104C)
Concorde, Intrepid, LHS & 300M
Coolant Replacement Interval ....................... 120,000 Miles
Coolant Capacity ................................. 9.4 Qts. (8.9L)\
Pressure Cap ........................................... 14-18 psi
Thermostat
Starts To Open .............................. 192-199
F (88-93C)
Fully Opens ....................................... 220F (104C)
Neon
Coolant Replacement Interval ........... 45,000 Miles Or 36 Months
Coolant Capacity ................................. 7.4 Qts. (7.0L)\
Pressure Cap ........................................... 14-18 psi
Thermostat
Starts To Open .............................. 192-199
F (88-93C)
Fully Opens ....................................... 220F (104C)
Page 628 of 1691
![DODGE RAM 1999 Service Repair Manual Talon
Coolant Replacement Interval ........... 30,000 Miles Or 24 Months
Coolant Capacity ................................. 7.4 Qts. (7.0L)\
Pressure Cap
VIN F .........................](/img/12/56915/w960_56915-627.png "DODGE RAM 1999 Service Repair Manual Talon
Coolant Replacement Interval ........... 30,000 Miles Or 24 Months
Coolant Capacity ................................. 7.4 Qts. (7.0L)\
Pressure Cap
VIN F .........................")
Talon
Coolant Replacement Interval ........... 30,000 Miles Or 24 Months
Coolant Capacity ................................. 7.4 Qts. (7.0L)\
Pressure Cap
VIN F ................................................. 11-15 psi
VIN Y ................................................. 14-18 psi
Thermostat
Starts To Open
VIN F ............................................ 180
F (82C)
VIN Y ............................................ 195F (91C)
Fully Opens
VIN F ............................................ 203
F (95C)
VIN Y ........................................... 216F (102C) \
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COOLING SYSTEM SPECIFICATIONS - TRUCKS \
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Application Specification
Coolant Replacement Interval ............. 45,000 Miles Or 36 Months
Coolant Capacity ( 1)
Caravan, Town & Country, & Voyager
2.4L ...................................... ( 2) 11.2 Qts. (10.6L)
3.0L ...................................... ( 2) 13.0 Qts. (12.3L)
3.3L & 3.8L ............................... ( 2) 13.2 Qts. (12.5L)
Dakota
2.5L ............................................ 9.8 Qts. (9.3L)\
3.9L .......................................... 14.0 Qts. (13.2L)\
5.2L .......................................... 14.3 Qts. (13.5L)\
5.9L ................................................. 14.6L (13.7L)\
Durango
3.9L .......................................... 14.0 Qts. (13.2L)\
5.2L & 5.9L ...................................... 14.3 Qts. (13.5L)\
Ram Pickup
3.9L, 5.2L & 5.9L (Gasoline) .................. 20.0 Qts. (18.9L\
)
5.9L (Diesel) ................................. 24.0 Qts. (22.7L\
)
8.0L .......................................... 26.0 Qts. (24.6L)\
Ram Van/Wagon
3.9L ........................................... 10.4 Qts. (9.8L)\
5.2L .......................................... 13.1 Qts. (12.4L)\
5.9L
With Rear Heater ............................ 14.1 Qts. (13.3L)\
Without Rear Heater ......................... 13.1 Qts. (12.4L)\
Pressure Cap ............................................. 14-16 psi
Thermostat
Diesel Engines
Starts To Open ..................................... 181
F (83C)
Fully Open ............................................ 203F (95C)
Gasoline Engines
Starts To Open ..................................... 192
F (89C)
Fully Opens ....................................... 220F (104C)
( 1) - Capacities listed are approximate.
( 2) - Capacity includes heater and coolant recovery tank. Add 2 qts.
(1.9L) for models equipped with rear heater.
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Page 629 of 1691
![DODGE RAM 1999 Service Repair Manual
3.9 L V 6, 5 .2 L & 5 .9 L V 8 - V IN [ T , X , Y , Z ]
1 999 D odge P ic ku p R 1500
1998-99 ENGINES
CHRY - 3.9L V6, & 5.2L & 5.9L V8
Chrysler Corp. Dakota, Du](/img/12/56915/w960_56915-628.png "DODGE RAM 1999 Service Repair Manual
3.9 L V 6, 5 .2 L & 5 .9 L V 8 - V IN [ T , X , Y , Z ]
1 999 D odge P ic ku p R 1500
1998-99 ENGINES
CHRY - 3.9L V6, & 5.2L & 5.9L V8
Chrysler Corp. Dakota, Du")
3.9 L V 6, 5 .2 L & 5 .9 L V 8 - V IN [ T , X , Y , Z ]
1 999 D odge P ic ku p R 1500
1998-99 ENGINES
CHRY - 3.9L V6, & 5.2L & 5.9L V8
Chrysler Corp. Dakota, Durango, Ram Pickup, Ram Van/Wagon
Jeep Grand Cherokee
ENGINE IDENTIFICATION
Engine may be identified by eighth character of Vehicle
Identification Number (VIN) stamped on metal tab located near lower
left corner of windshield. See ENGINE IDENTIFICATION CODES table.
Engine serial number may be required when ordering
replacement parts. Engine serial number is located on left front
corner of cylinder block just below cylinder head.
ENGINE IDENTIFICATION CODES
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Engine Code
3.9L PFI ......................................................... X
5.2L PFI ......................................................... Y
5.2L MFI CNG ..................................................... T
5.9L PFI
Light Duty Cycle ............................................... Z
Heavy Duty Cycle ( 1) ........................................... 5
( 1) - Heavy Duty Cycle (HDC) engine uses an engine mounted air
injection pump.
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SPECIAL ENGINE MARKS
Information identifying undersize and oversize components is
found at various engine locations and is decoded as follows:
Crankshaft & Rod Journals
The letter "M" (main) or "R" (rod) followed by number
indicates which main or rod bearing journal is .001" (.02 mm)
undersize. The mark is stamped on No. 6 crankshaft counterweight on 3.
9L, No. 8 crankshaft counterweight on 5.2L and No. 3 crankshaft
counterweight on 5.9L engines.
Cylinder Block - Letter "A" following engine serial number
indicates .020" (.51 mm) oversize cylinder bores:
* A diamond-shaped stamp, located on top pad at front of engine
and stamped on flat area of each oversize lifter bore,
indicates .008" (.20 mm) oversize lifters.
* A stamp "X" indicates .005" (.13 mm) oversize valve stems.
The stamp is found on machined pad, near two 3/8" tapped
holes on each end of cylinder head.
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
Hydraulic valve lifters are used. No valve adjustment is
required.
Page 630 of 1691
TROUBLE SHOOTING
NOTE: To trouble shoot mechanical engine components, see
appropriate table in TROUBLE SHOOTING article in GENERAL
INFORMATION.
REMOVAL & INSTALLATION
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.
NOTE: For installation reference, label all electrical connectors,
vacuum hoses and fuel lines before removal. Also place mating
marks on engine hood and other major assemblies before
removal.
FUEL PRESSURE RELEASE
CAUTION: Fuel system is under pressure. Pressure must be released
before servicing fuel system components.
Gasoline
1) Disconnect negative battery cable. Loosen fuel tank cap to
release tank pressure. Press on filler tube flap to relieve any
additional tank pressure.
NOTE: Fuel filler tube has spring-loaded flap located below fuel
fill cap to serve as secondary seal if fuel fill cap is not
tightened. It is part of EVAP monitor system when vehicle is
equipped with leak detection pump (LDP). Vehicle may be
equipped with flap installed into fuel filler tube even if
vehicle is NOT equipped with LDP and EVAP monitor system.
2) Remove fuel pump relay from Power Distribution Center
(PDC). For location of relay, refer to label on underside of PDC
cover. Start and run engine until it stalls. Attempt restarting engine
until it will no longer run.
3) Unplug connector from an injector. Attach one end of a
jumper wire (18 gauge or smaller) with alligator clips to either
injector terminal. Connect other end of jumper wire to positive side
of battery. Connect one end of a second jumper wire to remaining
injector terminal.
WARNING: Powering an injector for more than a few seconds will
permanently damage injector.
4) Touch other end of second jumper wire to negative terminal
of battery for no more than a few seconds. Place a rag below fuel
line. Disconnect quick-connect fitting at fuel rail. See FUEL LINE
DISCONNECT FITTINGS. Return fuel pump relay to PDC.
Compressed Natural Gas Fuel Tube Purging (5.2L)
1) Close control valve (clockwise) on all fuel cylinders.
Open manual shutoff valve (open when handle is parallel to fuel
tubes).
2) Start and operate engine until it runs out of fuel.
Attempt 3 more engine starts. If check valve or fuel fill receptacle