Distributor DODGE RAM 1999 Service User Guide
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
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Sensor (8.0L) On thermostat housing.
Engine Oil Pressure Sensor
(Diesel) On left side of engine, near
ECM.
Engine Oil Pressure Sensor
(3.9L) Near distributor.
Engine Oil Pressure Sensor
(5.2L) Near distributor.
Engine Oil Pressure Sensor
(5.9L) Near distributor.
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![DODGE RAM 1999 Service User Guide 3.8L L SFI DIS (3)
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3.8L L SFI DIS (3)
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Voyager & NS 2.4L B SFI DIS (
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(
1) - Engine may be identified by 8th character of Vehicle
Identification Number (VIN).
(
2) - Sequential Fuel Injection.
(
3) - Distributorless Ignition System.
(
4) - Engine code "G" indicates flex-fuel.
(
5) - Body code for standard pickup is BR. Body code for
Quad Cab is BE.
(
6) - Light-duty emissions.
(
7) - Heavy-duty emissions.
(
8) - Electronic fuel injection.
(
9) - Engine code "2" indicates Liquid Propane Gas (LPG).
(
10 ) - Engine code "T" indicates Compressed Natural Gas (CNG).
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Fig. 1: VIN Definition
MODEL/YEAR VIN CODE APPLICATIONS
MODEL/YEAR VIN CODE APPLICATION
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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.
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Fig. 2: Identifying Retainer Type Fuel Line Disconnect Fittings
Courtesy of Chrysler Corp.
ENGINE
Removal (Ram Van/Wagon)
1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect negative battery cable. Drain cooling system and engine
oil. Remove and discard oil filter.
2) Remove engine cover, air cleaner and oil dipstick.
Discharge A/C system (if equipped) using approved refrigerant
recovery/recycling equipment. Disconnect A/C lines at condenser, and
plug openings. Remove A/C compressor. Disconnect fan shroud.
3) Remove front bumper, grille and support brace. Disconnect
coolant hoses. Remove radiator, condenser and support as an assembly.
4) Remove upper fan shroud. Remove power steering pump with
hoses attached, and set aside. Remove air pump, spark plug wires and
distributor cap. Disconnect necessary electrical wiring, coolant hoses
and vacuum hoses. Disconnect fuel lines. See FUEL LINE DISCONNECT
Page 634 of 1691
FITTINGS. Remove air cleaner, throttle body, drive belts, generator,
fan and fan pulley. Remove lower fan shroud.
CAUTION: When removing engine, DO NOT lift engine by intake manifold.
5) Remove intake manifold. See INTAKE MANIFOLD. Raise and
support vehicle. Remove starter. Remove exhaust pipe and heat shields.
Disconnect transmission shift linkage. Remove crank sensor.
6) On A/T models, remove transmission inspection cover. Mark
torque converter-to-flexplate position for installation reference.
Remove torque converter-to-flexplate bolts. On M/T models, disconnect
clutch release mechanism at clutch housing.
7) Attach engine hoist to cylinder heads (at intake manifold
flanges). On all models, support transmission using a floor jack.
Remove transmission or clutch housing-to-cylinder block bolts. Remove
engine mount bolts. Remove engine out front of vehicle.
Installation
To install, reverse removal procedure. Tighten bolts/nuts to
specification. See TORQUE SPECIFICATIONS table. On A/T models, ensure
reference marks on torque converter and flexplate are aligned.
Evacuate and charge A/C system.
Removal ( Dakota 2WD, Durango 2WD, Grand Cherokee & Ram
Pickup)
1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect and remove battery. On all except Pickup, scribe hood
hinges for installation reference and remove hood.
2) On all models, drain cooling system. Disconnect coolant
hoses. Remove radiator, fan and shroud. Discharge A/C system (if
equipped) using approved refrigerant recovery/recycling equipment.
Disconnect A/C lines, and plug openings. On Pickup, remove upper core
support, transmission cooler and A/C condenser. On all models, remove
belt, air cleaner, vacuum lines, distributor cap and wiring.
3) Disconnect necessary electrical wiring. Disconnect fuel
lines. See FUEL LINE DISCONNECT FITTINGS. Remove throttle body and
linkage. Remove intake manifold. Remove starter, generator, charcoal
canister and horns. Disconnect power steering hoses (if equipped).
Raise and support vehicle. Drain oil. Disconnect exhaust pipe at
exhaust manifold.
4) On A/T models, remove transmission housing inspection
plate. Mark torque converter-to-flexplate position for installation
reference. Remove torque converter-to-flexplate bolts. Remove bracket
for transmission cooler lines.
NOTE: It may be necessary to remove manual transmission if
transmission cannot be supported using floor jack.
5) On M/T models, disconnect clutch release mechanism at
clutch housing. On all models, support transmission using a floor
jack. Remove transmission or clutch housing-to-cylinder block bolts.
Install engine lifting fixture, and attach chain.
CAUTION: When removing engine, DO NOT lift engine by intake manifold.
6) On Ram Pickup and Grand Cherokee, remove front engine
mount bolts. Remove engine from vehicle. On Dakota 2WD and Durango 2WD
models, remove front engine mount through-bolts. See Fig. 3. Remove
engine from vehicle.
Installation
To install, reverse removal procedure. Tighten bolts/nuts to
specification. See TORQUE SPECIFICATIONS table. On A/T models, ensure
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reference marks on torque converter and flexplate are aligned.
Evacuate and charge A/C system.
Removal (Durango 4WD & Dakota 4WD)
1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect and remove battery. Scribe hood hinges for installation
reference and remove hood.
2) Drain cooling system. Disconnect coolant hoses. Remove
radiator, fan and shroud. Discharge A/C system (if equipped) using
approved refrigerant recovery/recycling equipment. Disconnect A/C
lines, and plug openings. Remove air cleaner, vacuum lines,
distributor cap and wiring.
3) Disconnect necessary electrical wiring. Disconnect fuel
lines. See FUEL LINE DISCONNECT FITTINGS. Disconnect accelerator
linkage. Remove throttle body. Remove starter and generator.
Disconnect power steering hoses. Raise and support vehicle. Drain oil.
Disconnect exhaust pipe at exhaust manifold.
NOTE: Engine, transmission and front axle are connected and
supported with insulators and brackets. See Fig. 3.
4) On left side, remove 2 bolts attaching differential pinion
nose bracket-to-bellhousing bolts. Remove pinion nose bracket-to-
adapter bolts (located on top of differential, near pinion). Separate
engine from engine mount by removing engine mount through-bolt and nut
located on top of engine mount.
5) On right side, remove 2 axle-to-bracket bolts and bracket-
to-bellhousing bolt. Separate engine from engine mount by removing
engine mount through-bolt and nut located on top of engine mount.
Remove engine from vehicle.
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1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect negative battery cable. Drain cooling system. Disconnect
accelerator, cruise control, and transmission kickdown cables.
Disconnect fuel lines at throttle body. See FUEL LINE DISCONNECT
FITTINGS.
2) Remove engine cover (Ram Van/Wagon), air cleaner and
generator. Disconnect necessary electrical wiring, coolant hoses and
vacuum hoses. Remove distributor cap and spark plug wires. Remove
valve covers (if necessary).
3) Remove bolts, intake manifold and gaskets. Separate
throttle body from intake manifold (if necessary). Turn intake
manifold upside-down and remove plenum pan (if necessary).
Fig. 4: Plenum Pan Bolt Tightening Sequence
Courtesy of Chrysler Corp.
Installation
1) Install plenum pan and install all bolts finger tight.
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Removal
Remove air cleaner. Remove rocker arms. See ROCKER ARMS.
Remove intake manifold. See INTAKE MANIFOLD. Remove yoke retainer and
aligning yoke. Use Valve Lifter Remover/Installer (C-4129-A) to remove\
valve lifter(s).
NOTE: Cylinder block must be marked to indicate oversize valve
lifters. See SPECIAL ENGINE MARKS under ENGINE
IDENTIFICATION.
Inspection
Inspect components for damage. Measure lifter O.D. and bore
diameter in cylinder block. Determine oil clearance. Clearance must be
within specification. See VALVE LIFTERS table under ENGINE
SPECIFICATIONS. Cylinder block can be bored for oversize lifters.
CAUTION: DO NOT allow engine RPM to exceed fast idle until valve
lifters have filled with oil and become quiet.
Installation
1) Lubricate valve lifters and push rods before installing in
original locations. Ensure valve lifter is installed so oil feed hole
in side of valve lifter is facing upward, away from crankshaft.
2) Align yokes with arrow pointing toward camshaft. Install
yoke retainer, and tighten bolts to specification. See TORQUE
SPECIFICATIONS table.
CAMSHAFT
Removal
1) Remove engine. See ENGINE. Remove front cover and timing
chain. See FRONT COVER and TIMING CHAIN.
2) Remove valve lifters. See VALVE LIFTERS. Remove
distributor and distributor drive shaft. Remove camshaft thrust plate,
noting location of oil tab for installation reference. See Fig. 9.
Remove camshaft.
Fig. 9: Positioning Oil Tab
Courtesy of Chrysler Corp.
Inspection
Inspect camshaft and camshaft bearings for wear. Measure
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camshaft journal diameter and camshaft bearing I.D. Replace camshaft
or camshaft bearings if not within specification. See CAMSHAFT table
under ENGINE SPECIFICATIONS.
CAUTION: If camshaft is replaced, valve lifters must also be replaced.
Whenever new camshaft or valve lifters are installed,
manufacturer recommends addition of one pint of Chrysler
crankcase conditioner to engine oil for at least 500 miles to
aid break-in.
Installation
1) Ensure cup plugs are installed in oil passages behind
thrust plate. Lubricate camshaft and bearings, and install within 2"
(50.8 mm) of final installation location.
2) Install Camshaft Installer (C-3509), with long area behin\
d
distributor drive gear. See Fig. 10. This prevents camshaft from
contacting plug located in rear of cylinder block. Install distributor
lock bolt to retain camshaft installer.
3) Install camshaft thrust plate and oil tab. Ensure tang
engages with lower right hole of camshaft thrust plate. Tighten
camshaft thrust plate bolts to specification. See TORQUE
SPECIFICATIONS table. Top edge of oil tab should be flat against
camshaft thrust plate for timing chain lubrication. See Fig. 9.
4) To install remaining components, reverse removal
procedure. Check camshaft end play. If end play exceeds specification,
replace thrust plate. See CAMSHAFT table under ENGINE SPECIFICATIONS.
Ensure components are installed in original location.
CAUTION: DO NOT allow engine RPM to exceed fast idle until valve
lifters have filled with oil and become quiet.
Fig. 10: Installing Camshaft
Courtesy of Chrysler Corp.
CAMSHAFT BEARINGS
Page 645 of 1691
Removal & Installation
1) Use Camshaft Bearing Remover/Installer (C-3132-A) for
camshaft bearing replacement. Replace camshaft bearing if damaged or
if I.D. is not within specification. See CAMSHAFT table under ENGINE
SPECIFICATIONS.
2) Ensure oil holes are aligned. Ensure oil hole in No. 2
bearing aligns with oil hole to left cylinder head, and oil hole in
No. 3 bearing (3.9L) or No. 4 bearing (5.2L and 5.9L) aligns with oi\
l
hole to right cylinder head. Install NEW camshaft plug at rear of
cylinder block.
DISTRIBUTOR DRIVE SHAFT BUSHING
Removal
1) Rotate crankshaft so No. 1 cylinder is at TDC on
compression stroke. Remove distributor and distributor drive shaft.
Insert Bushing Puller (C-3052) into bushing, and thread down until
tight.
2) Hold bushing puller bolt, and rotate bushing puller nut
until distributor drive shaft bushing is removed.
Installation
1) Install NEW distributor drive shaft bushing over
burnishing end of Bushing Installer (C-3053). Insert bushing installer\
and distributor drive shaft bushing into cylinder block.
CAUTION: DO NOT ream distributor drive shaft bushing.
2) Using hammer, drive bushing installer and distributor
drive shaft bushing into cylinder block. Tighten nut to pull bushing
installer through distributor drive shaft bushing. Tightening nut
expands bushing tight in cylinder block and burnishes it to correct
size.
3) Ensure No. 1 cylinder is at TDC on compression stroke.
Install distributor drive shaft so slot is aligned toward left front
intake manifold bolt as viewed from rear of engine. Install
distributor with rotor positioned to No. 1 cylinder in distributor
cap.
REAR CRANKSHAFT OIL SEAL
Removal & Installation (Crankshaft Installed)
1) Remove oil pan. See OIL PAN. Remove oil pump. Remove rear
main bearing cap and discard lower rear crankshaft oil seal. Carefully
remove upper rear crankshaft oil seal and discard seal.
2) Lubricate new oil seal. Rotate upper rear crankshaft oil
seal in cylinder block with Yellow paint toward rear of engine.
Install lower rear crankshaft oil seal in main bearing cap with Yellow
paint toward rear of engine.
3) To prevent oil leakage, apply one drop of Loctite 515
sealant next to oil seal on main bearing cap surface before
installing. Apply silicone adhesive sealant at bearing cap-to-cylinder
block joint. See Fig. 11. Install main bearing cap, and tighten bolts
to specification. See TORQUE SPECIFICATIONS table. To install
remaining components, reverse removal procedure.
Removal & Installation (Crankshaft Removed)
1) Remove rear crankshaft oil seals from cylinder block and
main bearing cap. Lubricate oil seal. Install rear crankshaft oil
seals with Yellow paint toward rear of engine.
2) To prevent oil leakage, apply one drop of Loctite 515
sealant next to oil seal on main bearing cap surface before
installing. Apply silicone adhesive sealant at bearing cap-to-cylinder