coolant level DODGE RAM 1999 Service User Guide

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

Brake On/Off (BOO) Switch ................... Cruise Control Systems\
Engine Performance
Shift Interlock Systems
Buzzer Module ...................................... Warning Systems
Camshaft Position (CMP) Sensor .................. Engine Performance\
Central Control Module ........................... Anti-Theft System
Clockspring ............................... Air Bag Restraint System
Cruise Control Systems
Steering Column Switches
Clutch Pedal Position Switch .............................. Starters
Clutch Start Switch ....................................... Starters
Combination Meter ......................... Analog Instrument Panels
Constant Control Relay Module (CCRM) ............ Engine Performance\
Electric Cooling Fans
Convenience Center .............................. Power Distribution
Illumination/Interior Lights
Convertible Top Motor ........................ Power Convertible Top
Convertible Top Switch ....................... Power Convertible Top
Crankshaft Position (CKP) Sensor ................ Engine Performance\
Cruise Control Module ....................... Cruise Control Systems
Cruise Control Switch ....................... Cruise Control Systems
Condenser Fan Relay(s) ....................... Electric Cooling Fans\
Data Link Connector (DLC) ....................... Engine Performance\
Daytime Running Lights Module ............... Daytime Running Lights
Exterior Lights
Defogger Relay ................................ Rear Window Defogger
Diagnostic Energy Reserve Module (DERM) ... Air Bag Restraint System\
Discriminating Sensor (Air Bag) ........... Air Bag Restraint System\
Distributor ..................................... Engine Performance
Door Lock Actuators ............................... Power Door Locks
Remote Keyless Entry
Door Lock Relay(s) ................................ Power Door Locks\
Electrochromic Mirror ................................ Power Mirrors
Electronic Level Control (ELC)
Height Sensor .............................. Electronic Suspension
Electronic Level Control (ELC) Module ........ Electronic Suspension\
Engine Coolant Temperature (ECT)
Sending Unit ............................ Analog Instrument Panels
Engine Coolant Temperature (ECT) Sensor ......... Engine Performance\
Engine Control Module ........................... Engine Performance
Generators & Regulators
Starters
ETACS ECU .......................................... Warning Systems
Power Windows
Remote Keyless Entry
Evaporative (EVAP) Emissions Canister ........... Engine Performance\
EVAP Canister Purge Solenoid .................... Engine Performance
EVAP Canister Vent Solenoid ..................... Engine Performance
Exhaust Gas Recirculation (EGR) Valve ........... Engine Performance\
Fuel Tank Vacuum Sensor ......................... Engine Performance
Fog Lights ....................................... Headlight Systems
Daytime Running Lights
Fog Light Relay .................................. Headlight Systems
Daytime Running Lights
Fuel Door Release Solenoid ................. Power Fuel Door Release
Fuel Gauge Sending Unit ................... Analog Instrument Panels
Fuel Injectors .................................. Engine Performance
Fuel Pump ....................................... Engine Performance
Fuel Pump Relay ................................. Engine Performance
Power Distribution
Fuse/Relay Block ................................ Power Distribution
Fusible Links ................................... Power Distribution
Generators & Regulators

   











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

Oil   











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Fuel Tank  Capacity  35 Gal. (132L) 











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

dipstick (if available) to measure level. 










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LUBRICATION SPECIFICATIONS - GAS
LUBRICATION SPECIFICATIONS TABLE - GAS







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Material  Condition  Specification 











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Engine Oil Ambient Temperature Above 0 \bF SAE 10W-30 

(
1)  (-18\bC) To Over 100\bF (38\bC)  












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Ambient Temperature Less Than  SAE 5W-30 

-20\bF (-29\bC) Up To 32\bF (0\bC) 











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Engine  All  50/50 Mixture Of 

Coolant   Distilled Water & 

  Ethylene Glycol 











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Brake Fluid  All  DOT 3 











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Automatic  All  ATF+2 Type 7176 

Transmission   

Fluid   











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Transfer Case All  ATF+2 Type 7176 

Fluid   Or DEXRON III ATF 











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Manual  NV-4500 75W-90 Synthc. API GL4 

Transmission










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Fluid  NV-3500  Mopar Manual 

  Transmission Fluid 











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Steering  All  Mopar Multi-Mileage 

Linkage   Lubricant 

Lubricant   











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Wheel Bearing All High Temperature Multi-

Grease   -Purporse EP Grease 











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Rear Axle &  All Mopar Hypoid Lubricant 

4x4 Frt. Axle  SAE 80W-90 

Lubricant (
2)  GL-5 Gear Lube 











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Power  All  Mopar Power Steering 

Steering   Fluid Or Equivalant 

Fluid (
3)   Petroleum Based 











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Clutch  All  Multipurpose Grease 

Linkage   NLGI Grade 2 E.P. 

Lubricant   











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A/C  All  R-134a 

CAUTION: If turbocharger failure exists, intercooler must be cleaned.
See INTERCOOLER under AIR INDUCTION SYSTEMS.
Removal
1) Disconnect negative battery cables. Disconnect air inlet
tube and exhaust pipe from turbocharger. Disconnect intercooler inlet
duct from turbocharger. See Fig. 2.
2) Disconnect and plug turbocharger oil supply line and
turbocharger oil drain line at turbocharger. Remove turbocharger
retaining nuts, turbocharger and gasket from exhaust manifold. Plug
all air intake openings.
Installation
1) Apply anti-seize compound on turbocharger mounting studs.
Using NEW gasket, install turbocharger. Install and tighten
turbocharger retaining nuts to specification. See TORQUE
SPECIFICATIONS.
2) Using NEW gasket, install turbocharger oil drain line on
turbocharger. Install and tighten turbocharger oil drain line bolts to
specification. See TORQUE SPECIFICATIONS.
CAUTION: Turbocharger must be pre-lubricated by pouring clean engine
oil in turbocharger oil supply line fitting on turbocharger
before starting the engine.
WARNING: DO NOT rotate turbine wheel in turbocharger with your finger,
as sharp edges may exist.
3) Pour 3 ozs. (60 cc) of clean engine oil into turbocharger\
oil supply line fitting on turbocharger while using soft object to
rotate turbine wheel in turbocharger. This must be done to pre-
lubricate the turbocharger.
4) Install turbocharger oil supply line on turbocharger and
tighten nut to specification. See TORQUE SPECIFICATIONS. To install
remaining components, reverse removal procedure. Tighten bolts/nuts to
specification. See TORQUE SPECIFICATIONS.
TURBOCHARGER WASTEGATE ADJUSTMENT
NOTE: For turbocharger wastegate adjustment, see CONTROL ROD
ADJUSTMENT under TURBOCHARGER WASTEGATE in ON-VEHICLE
ADJUSTMENTS - DIESEL article.
ENGINE SENSORS & SWITCHES
ENGINE COOLANT TEMPERATURE SENSOR
Removal & Installation
1) Engine coolant temperature sensor is located at front of
cylinder head near thermostat. See Fig. 3.
2) Partially drain cooling system until coolant level is
below the cylinder head. Disconnect ECT sensor electrical connector.
Remove ECT sensor from cylinder head. Discard "O" ring. To install,
reverse removal procedure. Use new "O" ring.
CRANKSHAFT POSITION SENSOR (CKP)
NOTE: Crankshaft Position (CKP) sensor may be referred to as engine\
speed sensor.
Removal & Installation
1) CKP sensor is located on left rear side of engine block

1) Partially drain cooling system. Engine coolant temperature
sensor is located on front of intake manifold, near inside of
generator and contains a Tan/Black wire and a Black/Light Blue wire in
the electrical connector.
2) On 3.9L, remove engine cover and air cleaner housing from
inside of vehicle for access to engine coolant temperature sensor. On
5.2L and 5.9L, engine coolant temperature sensor may be serviced from
front of vehicle without removing engine cover and air cleaner
housing.
3) On all models, disconnect electrical connector at engine
coolant temperature sensor. It may be necessary to use a coat hanger
and fabricate an "L" shaped tool about 8" (203 mm) long to disconnect
electrical connector by placing hook part of tool under electrical
connector and pulling electrical connector upward from engine coolant
temperature sensor. Remove engine coolant temperature sensor.
Installation
To install, reverse removal procedure. Tighten engine coolant
temperature sensor to specification. See TORQUE SPECIFICATIONS. Fill
cooling system.
FUEL LEVEL SENSOR
Removal & Installation
See FUEL LEVEL SENSOR under FUEL SYSTEM.
INTAKE AIR TEMPERATURE (IAT) SENSOR
NOTE: Intake air temperature sensor may also be referred to as
intake manifold air temperature sensor.
Removal & Installation (Dakota, Durango & Ram Pickup)
1) IAT sensor is screwed into the intake manifold. See Fig. 4
, 5 or 6. Remove air inlet duct or air cleaner assembly for access to
IAT sensor if necessary. Disconnect electrical connector at IAT
sensor. Remove IAT sensor from intake manifold.
2) To install, reverse removal procedure. Tighten IAT sensor
to specification. See TORQUE SPECIFICATIONS.
Removal & Installation (Ram Van & Ram Wagon)
1) IAT sensor is screwed into the intake manifold. See Fig. 5
. On 3.9L, remove engine cover and air cleaner housing from inside of
vehicle for access to IAT sensor. On 5.2L and 5.9L, IAT sensor may be
serviced from front of vehicle without removing engine cover and air
cleaner housing.
2) On all models, disconnect electrical connector at IAT
sensor. Remove IAT sensor from intake manifold. To install, reverse
removal procedure. Tighten IAT sensor to specification. See TORQUE
SPECIFICATIONS.
Fig. 4: Locating Intake Air Temperature (IAT) Sensor (Dakota 2.5L)
Courtesy of Chrysler Corp.

SCHEDULED SERVICES - NORMAL SERVICE (DIESEL)

1999 D odge P ic ku p R 1500
1997-99 MAINTENANCE
Chrysler Maintenance & Service Intervals
Diesel Engines
Normal Service
DODGE; RAM PICKUP Cummins Turbo Diesel: 5.9L VIN [D]
* READ THIS FIRST *
Before preforming maintenance on vehicle, ensure that all
cautions and warnings have been observed to prevent vehicle damage or
personal injury. See CAUTIONS & WARNINGS in MAINTENANCE INFORMATION
article in this section.
Introduction
The frequency of scheduled inspection and maintenance
services in this article are based on normal vehicle usage ONLY. The
following Severe conditions are NOT taken into account:
* Frequent short driving less than 5 Miles (8 Km).
* Frequent driving in dusty conditions.
* Frequent trailer towing.
* Extensive idling.
* More than 50% of your driving is at sustained high speeds
during hot weather, above 90
F (32C).
If the vehicle is operated mainly under any of these
conditions, this Normal service schedule article is inadequate. DO NOT
USE. Instead, use the Severe service schedule: See
SCHEDULED SERVICES - NORMAL SERVICE (DIESEL) .
6,000 MILE (10,000 KM)/6 MONTH NORMAL SERVICE
6,000 MILE (10,000 KM)/6 MONTH NORMAL SERVICE
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INSPECT 

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 Exhaust System 


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 Brake Hoses 


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 Engine Coolant Level, Hoses & Clamps 

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SERVICE 

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 Rotate Tires 


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 Lubricate Steering Linkage 

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REPLACE 

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 Engine Oil 


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 Engine Oil Filter 

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LUBRICATION SPECIFICATIONS 

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Material  Condition  Specification 

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 Engine Oil Ambient Temperature Above 10F SAE 15W-40 

(
1)  (-12C) To Over 30F (-1C)  


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Ambient Temperature Less Than  SAE 10W-30 

0F (-18C) To Over 30F(-1C) 


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Ambient Temperature Less Than  With Block Heater: 

-10F(-23C) Up To 0F (-18C) SAE 10W-30 

  Without Block Heater: 

  SAE 5W-30 

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Engine  All  50/50 Mixture Of 

Coolant   Distilled Water & 

  Ethylene Glycol 

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Brake Fluid  All  DOT 3 

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Steering  All  Mopar Multi-Mileage 

Linkage   Lubricant 

Lubricant   

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(
1) - SAE 10W-30 engine oil is preferred for use in all Dodge 

trucks. Use only API approved oil with Starburst Symbol. 

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FLUID CAPACITIES 

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Item  Condition  Specification (1) 

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Engine Oil  Capacity, Upper Safe Mark  10 Qts. (9.5L) 


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 Capacity, Lower Safe Mark  8 Qts. (7.5L) 

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Engine  Drained  26 Qts. (24.5L) 

Coolant   

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

dipstick (if available) to measure level. 
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12,000 MILE (19,000 KM)/12 MONTH NORMAL SERVICE
12,000 MILE (19,000 KM)/12 NORMAL SERVICE
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INSPECT 

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 Exhaust System 


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 Brake Hoses 


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 Engine Coolant Level, Hoses & Clamps 


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 Water Pump Weep Hole For Blockage 

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SERVICE 

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 Rotate Tires 


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 Lubricate Steering Linkage 


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 Clean Fuel Strainer 

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REPLACE 

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 Engine Oil 


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 Fuel Filter 

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LUBRICATION SPECIFICATIONS 

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Material  Condition  Specification 

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Engine Oil Ambient Temperature Above 10F SAE 15W-40 

(
1)  (-12C) To Over 30F (-1C)  


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Ambient Temperature Less Than  SAE 10W-30 

0F (-18C) To Over 30F(-1C) 


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Ambient Temperature Less Than  With Block Heater: 

-10F(-23C) Up To 0F (-18C) SAE 10W-30 

  Without Block Heater: 

  SAE 5W-30 

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Engine  All  50/50 Mixture Of 

Coolant   Distilled Water & 

  Ethylene Glycol 

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Brake Fluid  All  DOT 3 

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Steering  All  Mopar Multi-Mileage 

Linkage   Lubricant 

Lubricant   

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(
1) - SAE 10W-30 engine oil is preferred. Use only API approved 

oil with Starburst Symbol. 

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FLUID CAPACITIES 

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Item  Condition  Specification (1) 

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Engine Oil  Capacity, Upper Safe Mark  10 Qts. (9.5L) 


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 Capacity, Lower Safe Mark  8 Qts. (7.5L) 

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Engine  Drained  26 Qts. (24.5L) 

Coolant   

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

dipstick (if available) to measure level. 
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18,000 MILE (29,000 KM)/18 MONTH NORMAL SERVICE
18,000 MILE (29,000 KM)18 MONTH NORMAL SERVICE
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VERIFY 

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Last Major Service Was Performed. 

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INSPECT 

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 Exhaust System 


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  Brake Hoses 


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 Engine Coolant Level, Hoses & Clamps 


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 Brake Linings 


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 Drive Belts 

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SERVICE 

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 Rotate Tires 


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 Lubricate Steering Linkage 

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REPLACE 

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 Engine Oil 


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 Engine Oil Filter 

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LUBRICATION SPECIFICATIONS 

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Material  Condition  Specification 

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Engine Oil Ambient Temperature Above 10F SAE 15W-40 

(
1)  (-12C) To Over 30F (-1C)  


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Ambient Temperature Less Than  SAE 10W-30 

0F (-18C) To Over 30F(-1C) 


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Ambient Temperature Less Than  With Block Heater: 

-10F(-23C) Up To 0F (-18C) SAE 10W-30 

  Without Block Heater: 

  SAE 5W-30 

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Engine  All  50/50 Mixture Of 

Coolant   Distilled Water & 

  Ethylene Glycol 

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Brake Fluid  All  DOT 3 

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Steering  All  Mopar Multi-Mileage 

Linkage   Lubricant 

Lubricant   

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(
1) - SAE 10W-30 engine oil is preferred. Use only API approved 

oil with Starburst Symbol. 

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FLUID CAPACITIES 

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Item  Condition  Specification (1) 

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Engine Oil  Capacity, Upper Safe Mark  10 Qts. (9.5L) 


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 Capacity, Lower Safe Mark  8 Qts. (7.5L) 

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Engine  Drained  26 Qts. (24.5L) 

Coolant   

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

dipstick (if available) to measure level. 
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24,000 MILE (38,000 KM)/24 MONTH NORMAL SERVICE
24,000 MILE (38,000 KM)/24 MONTH NORMAL SERVICE
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VERIFY 

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Last Major Service Was Performed. 

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INSPECT 

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 Exhaust System 


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 Brake Hoses 


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 Engine Coolant Level, Hoses & Clamps 


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 Front Wheel Bearings (4x2) 


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 Pump Weep Hole For Blockage 


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 Fan Hub 


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 Damper 

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SERVICE 

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 Rotate Tires 


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 Lubricate Steering Linkage 


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 Automatic Transmission Bands 


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 Clean Fuel Strainer 


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 Adjust Valve Lash Clearance 

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REPLACE 

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 Engine Oil 


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 Engine Oil Filter 


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 Fuel Filter 


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 Automatic Transmission Fluid & Filter 

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LUBRICATION SPECIFICATIONS 

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Material  Condition  Specification 

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Engine Oil Ambient Temperature Above 10F SAE 15W-40 

(
1)  (-12C) To Over 30F (-1C)  


\
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\
\


Ambient Temperature Less Than  SAE 10W-30 

0F (-18C) To Over 30F(-1C) 


\
\
\

\
\


Ambient Temperature Less Than  With Block Heater: 

-10F(-23C) Up To 0F (-18C) SAE 10W-30 

  Without Block Heater: 

  SAE 5W-30 

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Engine  All  50/50 Mixture Of