diesel DODGE RAM 1999 Service User Guide

Fig. 17: Transmission Wiring Diagram (Pickup 5.9L Diesel - 1 Of 2)

Fig. 18: Transmission Wiring Diagram (Pickup 5.9L Diesel - 2 Of 2)


F - B ASIC T E STIN G - D IE SEL

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Basic Diagnostic Procedures - Trucks - Diesel
Ram Pickup
INTRODUCTION
The following diagnostic steps will help prevent overlooking
a simple problem. This is also where to begin diagnosis for a no-start
condition.
The first step in diagnosing any driveability problem is
verifying the customer's complaint with a test drive under the
conditions the problem reportedly occurred.
Before entering self-diagnostics, perform a careful and
complete visual inspection. Most engine control problems result from
mechanical breakdowns or poor electrical connections. Before
condemning the computerized system, perform each test listed in this
article.
Two different module systems are used for powertrain control
of diesel engine. The Engine Control Module (ECM), located on left
side of engine, is used to control the fuel system. See Fig. 1. The
Fuel Pump Control Module (FPCM) located on pump, is a separate
component of ECM.
The Powertrain Control Module (PCM), located at right rear of\
engine compartment, is used for charging system, transmission and
speed control functions. CCD Bus circuits connect the various vehicle
control modules. These circuits are connected between ECM and PCM to
allow communication between modules.
Fig. 1: Locating Fuel System & Various Engine Components
Courtesy of Chrysler Corp.
PRELIMINARY INSPECTION & ADJUSTMENTS

VISUAL INSPECTION
1) Check Water-In-Fuel (WIF) sensor electrical connector for\
corrosion, damaged terminals or wiring and tight fit on engine wiring
harness. WIF sensor is located in bottom of fuel filter/water
separator. See Fig. 1.
2) Check for water in fuel filter/water separator by placing
drain pan below drain tube at fuel filter/water separator. See Fig. 1.
3) With engine not running, rotate handle on drain valve
forward, toward front of vehicle to OPEN position. Drain valve is
located near top of fuel filter/water separator. See Fig. 1. Drain
water from fuel filter/water separator.
4) If no water exists and a clean flow of diesel fuel exists,
rotate handle on drain valve back to CLOSE position. Go to next step.
If water exists, allow water to drain until clean flow of diesel fuel
exists. Rotate handle on drain valve back to CLOSE position. Go to
next step.
5) Verify fuel filter/water separator has been serviced
according to proper service schedule. See SERVICE & ADJUSTMENT
SPECIFICATIONS - TRUCKS article.
6) Check color of Filter Minder. Filter Minder is located on
top cover on air filter housing, just above air filter. DO NOT remove
air filter from air filter housing for inspection. If Yellow disc in
Filter Minder has reached Red zone, remove and inspect air filter. See
Fig. 2 . If air filter is dirty, replace air filter and reset Filter
Minder by pressing rubber button on top of Filter Minder.
NOTE: The Yellow disc in Filter Minder may reach Red zone if air
intake is restricted or air filter has become wet during
heavy rain or snow. If air filter has become wet, allow air
filter to dry during normal engine operation and reset Filter
Minder by pressing rubber button on top of Filter Minder.
7) Ensure intercooler inlet and outlet duct clamps are tight
and front of intercooler is not restricted with dirt. See Fig. 3.
Fig. 2: Identifying Filter Minder Components
Courtesy of Chrysler Corp.

13) On A/T models, ensure all electrical connectors are clean
and properly connected to electrical plugs on transmission case. On
all models, check for loose or defective electrical connections on
starter and starter solenoid.
MECHANICAL INSPECTION
Compression
Manufacturer does not provide information for checking
compression.
FUEL SYSTEM
AIR IN FUEL SYSTEM
NOTE: Air in the fuel system may cause hard starting, rough
running, excessive smoke, poor engine performance, engine
misfire, poor fuel economy and fuel knock. Air may enter fuel
system whenever fuel supply lines, fuel filter/water
separator, fuel injection pump, fuel injectors or high
-pressure fuel lines are removed or disconnected.
1) Inspect all low-pressure fuel lines from fuel tank to fuel
transfer pump, fuel heater and fuel filter/water separator for signs
of leakage. Inspect all high-pressure fuel lines for signs of leakage.
See FUEL INJECTOR & HIGH-PRESSURE FUEL LINES under FUEL SYSTEM.
2) After repairing fuel leak, bleed air from fuel system. See
FUEL LINE BLEEDING under FUEL SYSTEM in REMOVAL, OVERHAUL &
INSTALLATION - TRUCKS - DIESEL article.
FUEL HEATER
1) Fuel heater is located in fuel filter/water separator. See
Fig. 1 . Fuel heater uses a fuel heater temperature sensor for
controlling operation of the fuel heater.
2) A defective fuel heater may cause excessive wax build-up
in the fuel filter/water separator during cold ambient temperatures.
Wax build-up may cause hard starting, prevent engine from
accelerating, low power, Blue smoke or White smoke. For testing of
fuel heater and fuel heater temperature sensor, see SYSTEM & COMPONENT
TESTING - TRUCKS - DIESEL article.
FUEL HEATER RELAY
Ensure fuel heater relay, located in power distribution
center is installed correctly and that terminals are not corroded. For
fuel heater relay testing, see SYSTEM & COMPONENT TESTING - TRUCKS -
DIESEL article.
FUEL FILTER/WATER SEPARATOR
NOTE: A blocked or restricted fuel filter/water separator may cause
starting problems, prevent engine from accelerating, low
power or White smoke. If an excessive amount of water
collects in filter/separator in a short period of time, it
may be necessary to drain and clean fuel tank.
1) When ignition switch is first turned to ON position,
WATER-IN-FUEL (WIF) warning light should come on for 2 seconds to
perform bulb and wiring circuit test and then go off. WATER-IN-FUEL
(WIF) warning light is located on instrument panel, just below the

tachometer.
2) If WATER-IN-FUEL (WIF) warning light stays on, water
should be drained from fuel filter/water separator. To drain water
from fuel filter/water separator, ensure engine is not running. Place
drain pan below drain tube at fuel filter/water separator. See Fig. 1.
3) Rotate handle on drain valve forward, toward front of
vehicle to OPEN position. Drain valve is located near top of fuel
filter/water separator. See Fig. 1.
4) Allow water to drain until clean flow of diesel fuel
exists. Rotate handle on drain valve back to CLOSE position.
FUEL TRANSFER PUMP
NOTE: A defective fuel transfer pump may cause low power, hard
starting and White smoke. Check fuel transfer pump output
pressure (cranking and starting), pressure drop and fuel
supply.
Fuel Transfer Pump Preliminary Inspection
1) Check for restricted or leaking fuel supply line to fuel
transfer pump or fuel return line located on driver's side of engine.
See Fig. 1 . Repair fuel supply line or fuel return line if restricted
or leaking.
2) Check for fuel leaking from fuel transfer pump. Replace
fuel transfer pump if fuel is leaking. Check fuel transfer pump output
pressure.
Fuel Transfer Pump Output Pressure
1) Clean area around filter fitting plugs, then remove plugs.
See Fig. 7 . Install Test Fittings (AVU1-2). Install Fuel Pressure Test
Gauge (6828) at inlet port. See Fig. 7. To prevent engine starting,
remove fuel injection pump relay, located in power distribution
center.
2) Turn ignition switch to START position. Inlet pressure
should be 5-7 psi. Install fuel injection pump relay. Start engine.
Inlet pressure should be 10 psi. Using a scan tool, clear FTC. FTC may
set when relay is removed. Check pressure drop.
Fig. 7: Checking Fuel Transfer Pump Output Pressure
Courtesy of Chrysler Corp.
Pressure Drop Test
Turn engine off. Move pressure gauge from inlet port to

outlet port. See Fig. 7. Start engine. Outlet pressure should not be
more 5 psi (0.4 kg/cm) less than inlet pressure. If pressure drop is
more than 5 psi (0.4 kg/cm), replace fuel filter and retest pressure.
If pressure drop is less than 5 psi (0.4 kg/cm), check for fuel
supply restriction.
NOTE: Due to very small vacuum specifications, use a scan tool and
Periphal Expansion Port (PEP) module with 0-15 psi transducer\
to perform following test.
Fuel Supply Restriction Test
Ensure transfer pump pressure is okay. Disconnect fuel supply
line at fuel transfer pump inlet. Remove plastic clip from pump inlet
and install in end of fuel supply line. Install 3/8" Adapter Hose
(6631) between fuel supply line and pump inlet. Install transducer
from PEP module to "T" fitting on adapter. Connect scan tool to
module. Start engine. Check vacuum reading with engine at full
throttle with no load. If vacuum reading is less than 6 in. Hg, check
for fuel supply air leaks. If vacuum reading is 6 in. Hg or more,
check fuel line for damage, dents and kinks. Repair as necessary. If
no problem is found, remove fuel module from fuel tank and check for
obstructions. Repair as necessary.
NOTE: A 3' section of 1/4" I.D. clear tubing and a 1/8" NPT fitting
are required for the following test.
Fuel Supply Air Leak Test
Clean area around filter inlet fitting plug, then remove
plug. See Fig. 7. Install 1/8" NPT fitting with 1/4" nipple fitting in
test port. Attach clear hose with a clamp to fitting. Place other end
of hose in a fuel container. Turn ignition switch to START position,
then release to RUN position without starting engine. Fuel transfer
pump should run for 25 seconds. After hose has been purged, watch for
any air bubbles in hose. If no bubbles exist, system is okay. If
bubbles exist, check fuel line, fittings and fuel module in tank.
Repair as necessary.
OVERFLOW VALVE
1) Fuel transfer pump delivers more fuel to fuel injection
pump than needed. Surplus fuel is routed back to fuel tank by overflow
valve. Overflow valve is used to secure fuel return line to side of
fuel injection pump. See Fig. 1. A sticking check valve in the
overflow valve may result in low power. Pressure release is set at 14
psi. (1.0 kg/cm
). If outlet valve is stuck closed, a FTC may set.
2) Clean area around outlet valve and fuel return line.
Remove valve from pump and fitting. Using regulated air pressure, test
valve by blowing into valve inlet. Valve should open at 14-16 psi. (1.
0-1.1 kg/cm
). If valve does not open, replace valve. Reduce air
pressure to 10 psi. (0.7 kg/cm). Valve should close. If valve does
not close, replace valve. Using NEW gaskets, install valve through
banjo fitting into fuel injection pump. Tighten valve to 24 ft. lbs.
(30 N.m).
FUEL INJECTOR & HIGH-PRESSURE FUEL LINES
WARNING: DO NOT allow diesel fuel to contact hot engine when checking
fuel injector, as high exhaust temperatures could cause fire.
Use care when working around high-pressure fuel lines, as
fuel is under extreme pressure and could penetrate skin,
causing personal injury. Wear safety goggles and protective
clothing when checking fuel injectors.

NOTE: A leaking fuel injector or high-pressure fuel line may cause
a rough idle, Black smoke, poor engine performance, poor fuel
economy and fuel knock. Since a leaking high-pressure fuel
line may cause the same symptoms, check for leaking high
-pressure fuel line before checking fuel injector.
1) To determine which injector or line is malfuntioning,
start engine and check each cylinder output using scan tool. If scan
tool is not available, start engine and engine allow to idle. Loosen
high-pressure fuel line nut at each fuel injector in turn and listen
for a decrease in engine speed. Tighten high-pressure fuel line nut to
30 ft. lbs. (40 N.m). Go to next step.
2) To check for a leaking high-pressure fuel line, start
engine and allow engine to idle. Inspect high-pressure fuel lines and
connections for signs of fuel leakage by placing cardboard over high-
pressure fuel line and connection. Note if leak is being detected by
fuel being sprayed onto the cardboard. If leak exists, repair leak by
tightening high-pressure fuel line nut to 30 ft. lbs. (40 N.m) or
replacing high-pressure fuel line as necessary. If high-pressure fuel
line is replaced, bleed air from fuel system. See FUEL LINE BLEEDING
under FUEL SYSTEM in REMOVAL, OVERHAUL & INSTALLATION - TRUCKS -
DIESEL article. If no leaks are found, go to next step.
3) Remove suspect injector. See FUEL INJECTOR under FUEL
SYSTEM in REMOVAL, OVERHAUL & INSTALLATION - TRUCKS - DIESEL article.
Test injector with a diesel fuel injector tester. Follow tester
instructions. Replace fuel injector if fuel injector opening (pop)
pressure is not 4250-4750 psi (299-334 kg/cm
). Replace injector if
any leaks are noted at 291 psi (20 kg/cm) less than opening (pop)
pressure. Inspect injector for burrs, cracks, wear and plugging. Check
spray pattern. If any problems are noted, replace injector.
FUEL INJECTION PUMP TIMING
Improper fuel injection pump timing may result in low power,
excessive smoke and poor fuel economy. To check fuel injection pump
timing, see FUEL INJECTION PUMP TIMING in ADJUSTMENTS - TRUCKS -
DIESEL article.
INTAKE MANIFOLD AIR HEATER
NOTE: Intake manifold air heater is used to heat incoming air
before entering each cylinder. Warming of incoming air aids
in engine starting and improved driveability during cold
ambient temperatures. Engine Control Module (ECM) uses input
signals from various sensors for controlling intake manifold
air heater relays.
SUMMARY
If no faults were found while performing basic diagnostic
procedures, proceed to SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS
article. If no diagnostic trouble codes are found in self-diagnostics,
proceed to TROUBLE SHOOTING - NO CODES - DIESEL article for diagnosis
by symptom (i.e., ROUGH IDLE, NO START, etc.) or intermittent
diagnostic procedures.

BRAK E S YSTE M
1999 D odge P ic ku p R 1500
1998-99 BRAKES
CHRY - Disc & Drum - Trucks & Vans - Except FWD
Dakota, Ram Pickup, Ram Van
DESCRIPTION & OPERATION
All models are equipped with single-piston, sliding-caliper
front disc brakes with ventilated rotors. All models utilize self-
adjusting rear drum brakes. Rear Wheel Anti-Lock (RWAL) brake system
is standard on all models. Optional 4-wheel Anti-Lock (4WAL) brake
system is available on all models.
System also includes power brake booster, dual-reservoir
master cylinder and combination valve. Combination valve consists of
metering valve and pressure differential switch.
Models with diesel engine include a gear-driven vacuum pump.
Depending on speed of engine, pump produces 8-25 in. Hg. Models
without full-floating rear axle use 9", 10" or 11" single-anchor rear
brakes. Models with full-floating rear axle use 12" or 13" single-
anchor rear brakes.
NOTE: For information on Anti-Lock Brake Systems (ABS), see
appropriate ANTI-LOCK article.
BLEEDING BRAKE SYSTEM
BLEEDING PROCEDURES
Complete Brake System
Before bleeding system, exhaust all vacuum from power unit by
depressing brake pedal several times. Bleed master cylinder using
bleeder screws (if equipped). Bleed wheel cylinders and calipers in
sequence. See BLEEDING SEQUENCE table.
BLEEDING SEQUENCE









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Application Sequence
1999 Dakota & Ram Van .......... Master Cylinder, Combination Valve,
RR, LR, RF & LF
All Other Models ............... Master Cylinder, Combination Valve,
Rear Anti-Lock Valve, RR, LR, RF & LF









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Master Cylinder (Bench Bleeding)
1) Bench bleed master cylinder before installation. Place
master cylinder in soft-jaw vise. Install bleeder tubes in both
outlets of master cylinder. See Fig. 1.
2) Fill master cylinder with clean brake fluid. Ensure ends
of bleeder tubes are submerged in brake fluid.
3) Using a wood dowel, apply and release master cylinder
until no air bubbles exist in brake fluid flow. Leave bleeder tubes
installed on master cylinder during installation. Install master
cylinder. Remove bleeder tubes, and connect brakelines. Bleed brake
system if necessary.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Axle Adjustment Nut .............................. 120-140 (163-190)\
Axle Shaft Flange Or Support Plate Mounting Nuts
Dakota .................................................. 47 (64)\
Ram Pickup ........................................ 35-50 (48-68)\
Ram Van ................................................ 85 (115)\
Bearing/Hub Assembly Mounting Bolts ...................... 125 (170)\
Brake Booster Mounting Nuts
Dakota & Ram Pickup ...................................... 21 (29)\
Ram Van .................................................. 13 (18)\
Brake Hose Front Bolt (Dakota) ............................. 21 (29\
)
Brake Hose Front Fitting (Dakota) .......................... 12 (16\
)
Brake Hose Rear Fitting (Dakota) ........................... 14 (19\
)
Brakeline Fittings Combination Valve
Dakota ................................................... 14 (19)\
Ram Pickup ......................................... 14-17 (19-23)\
Brakeline Fittings Master Cylinder
Dakota ................................................... 14 (19)\
Ram Pickup ......................................... 14-17 (19-23)\
Brakeline Fittings Wheel Cylinder
Dakota ................................................... 12 (16)\
Ram Pickup ............................................... 10 (14)\
Brake Pedal Shaft Nut (Ram Van) ............................ 40 (54\
)
Caliper Adapter Bolts (Ram Van)
1/2 Ton ................................................ 130 (176)\
3/4 & 1 Ton ............................................ 210 (285)\
Caliper Mounting Bolts
Dakota (Guide Pins) ...................................... 22 (30\
)
Ram Pickup ............................................... 38 (52)\
Ram Van .................................................. 24 (33)\
Combination Valve Mounting Bolt (Ram Pickup) ............... 17 (23\
)
Diesel Hydraulic Booster Hoses (Ram Pickup) ................ 23 (31\
)
Diesel Hydraulic Booster Lines (Ram Pickup) ................ 21 (29\
)
Diesel Hydraulic Booster Mounting Bolts (Ram Pickup) ....... 21 (29\
)
Drive Flange Lock Nuts (4WD) ............................... 65 (88\
)
Master Cylinder Nuts
Dakota
1998 .................................................... 21 (29)\
1999 .................................................... 13 (18)\
Ram Pickup ............................................... 21 (29)\
Ram Van .................................................. 17 (23)\
Park Brake Pedal Assembly Mounting Bolts/Nuts
Ram Pickup ............................................... 21 (29)\
Ram Van .................................................. 40 (54)\
Pivot Pin .................................................. 30 (41)\
Power Booster Lock Nuts
Dakota & Ram Pickup ...................................... 21 (29)\
Ram Van .................................................. 13 (18)\
Proportioning Valve Brake Hose (Ram Pickup) ................ 23 (31\
)
Proportioning Valve Brakelines (Ram Pickup) .......... 14-17 (19-23\
)
Proportioning Valve Mounting Nuts (Ram Pickup) ............. 25 (34\
)
Wheel Bearing Outer Lock Nut (4WD) ......................... 65 (88\
)
Wheel Cylinder Mounting Bolts
1/4" Bolts (Dakota) ...................................... 11 (15\
)
5/16" Bolts (Dakota) ..................................... 16 (22\
)
Ram Pickup & Ram Van ..................................... 15 (20)\