engine coolant 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
Page 559 of 1691
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - Refer to manufacturer's diagnostic trouble code procedure
and require repair or replacement of affected
component(s).
( 2) - Determine cause and correct prior to repair or replacement
of part.
( 3) - Determine source of contamination, such as engine
coolant, fuel, metal particles, or water. Require
repair or replacement.
( 4) - Inoperative includes intermittent operation or out of OEM
specification. Some components may be serviceable; check
for accepted cleaning procedure.
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CRUISE CONTROL BRAKE SWITCHES
See SWITCHES.
CRUISE CONTROL CABLES
See CRUISE CONTROL LINKAGES AND CABLES .
CRUISE CONTROL CLUTCH SWITCHES
See SWITCHES.
CRUISE CONTROL LINKAGES AND CABLES
CRUISE CONTROL LINKAGE AND CABLE INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Bent .................... A .. Require repair or replacement.
Binding ................. A .. Require repair or replacement.
Bracket bent, affecting
performance ............ A .. Require repair or replacement.
Bracket bent, not
affecting performance .. .. ........ No service suggested or
required.
Bracket broken, affecting
performance ............ A ............ Require replacement.
Bracket broken, not
affecting performance .. .. ........ No service suggested or
required.
Bracket corroded,
affecting performance .. A .. Require repair or replacement.
Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Page 611 of 1691
These 3 orifices are opened and closed by electric solenoids. The
solenoids are, in turn, controlled by the Electronic Control Module
(ECM). When a solenoid is energized, the armature with attached shaft
and swivel pintle is lifted, opening the orifice. See Fig. 11.
The ECM uses inputs from the Coolant Temperature Sensor
(CTS), Throttle Position Sensor (TPS) and Mass Airflow (MAF) senso\
rs
to control the EGR orifices to make 7 different combinations for
precise EGR flow control. At idle, the EGR valve allows a very small
amount of exhaust gas to enter the intake manifold. This EGR valve
normally operates above idle speed during warm engine operation.
Verify EGR valve is present and not modified or purposely
damaged. Ensure thermal vacuum switches, pressure transducers, speed
switches, etc., (if applicable) are not by-passed or modified. Ensure
vacuum hose(s) to EGR valve is not plugged. Ensure electrical
connector to EGR valve is not disconnected.
Fig. 11: Typical Digital EGR Valve
Courtesy of General Motors Corp.
Integrated Electronic EGR Valve
This type functions similar to a ported EGR valve with a
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 User Guide 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 User Guide 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 633 of 1691
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
Page 635 of 1691
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.
Page 637 of 1691
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.
Page 640 of 1691
CAUTION: Install NEW studs in cylinder head if studs came out when
removing exhaust manifold. Apply sealant to coarse threads of
studs before installing in head.
Installation
To install, reverse removal procedure. Ensure conical washers
are installed in original locations. Tighten bolts/nuts to
specification, starting at center and working outward. See TORQUE
SPECIFICATIONS table.
CYLINDER HEAD
Removal
1) On Van, remove engine cover and heat shields. On all
models, disconnect battery, and drain coolant. Remove generator
bracket support rod and generator. Remove intake and exhaust manifold.
See INTAKE MANIFOLD and EXHAUST MANIFOLD.
2) Remove rocker arms and push rods. See ROCKER ARMS. Remove
cylinder head bolts, cylinder head and gasket.
Inspection
Check cylinder head warpage. Repair or replace cylinder head
if warpage exceeds specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS.
Installation
To install, reverse removal procedure. Tighten cylinder head
bolts, to specification and in sequence, using 3 steps. See Fig. 7.
See TORQUE SPECIFICATIONS table.
Fig. 7: Cylinder Head Bolt Tightening Sequence
Courtesy of Chrysler Corp.
FRONT COVER OIL SEAL
Page 641 of 1691
Removal
Disconnect negative battery cable. Remove drive belts from
crankshaft pulley. Remove fan and shroud. Remove crankshaft pulley and
vibration damper. Pry oil seal from front cover.
Installation
1) Use Seal Installer (6635) for seal installation. Installe\
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should fit with minimum interference. If installer does not fit, front
cover must be removed and installed properly.
2) Position small diameter of oil seal over seal installer.
Using vibration damper bolt, tighten seal installer to draw seal into
position. Remove vibration damper bolt and seal installer. To complete
installation, reverse removal procedure.
FRONT COVER
Removal
1) Disconnect battery. Drain coolant. Remove power steering
pump (if equipped). Remove water pump. See WATER PUMP.
2) Remove crankshaft pulley and vibration damper. Loosen oil
pan bolts. Remove oil pan-to-front cover bolts on each side of oil
pan. Remove bolts, front cover and gasket. DO not damage oil pan
gasket.
Installation
1) Ensure sealing surfaces are clean. Apply a 1/8" (3.17 mm)\
bead of RTV sealant to oil pan gasket. Install gasket, front cover and
bolts. DO NOT tighten bolts at this time.
2) Install front cover oil seal. See FRONT COVER OIL SEAL.
Tighten front cover, oil pan and then vibration damper bolts to
specification. See TORQUE SPECIFICATIONS table. To complete
installation, reverse removal procedure.
TIMING CHAIN
Inspection
1) Remove front cover. See FRONT COVER. Position ruler at
camshaft sprocket, near timing chain link, to check timing chain
stretch.
NOTE: When applying torque to camshaft sprocket bolt, DO NOT allow
crankshaft to move. It may be necessary to hold crankshaft.
2) Place torque wrench on camshaft sprocket bolt. Apply 30
ft. lbs. (41 N.m) torque with cylinder heads installed, or 15 ft. lbs.\
(20 N.m) with cylinder heads removed, on camshaft sprocket bolt in
direction of engine rotation. Note reading on ruler.
3) Apply same amount of torque in opposite direction and note
amount of timing chain movement on ruler. If movement exceeds 1/8" (3.
17 mm), replace timing chain.
Removal
Rotate crankshaft so timing marks are aligned. See Fig. 8.
Remove camshaft sprocket bolt, camshaft sprocket, timing chain and
crankshaft sprocket.
Installation
1) Install timing chain and sprockets. Ensure timing marks
are aligned. See Fig. 8. Install camshaft sprocket bolt and tighten to
specification. See TORQUE SPECIFICATIONS table.
2) Ensure camshaft end play is within specification. See
CAMSHAFT table under ENGINE SPECIFICATIONS. If end play is not within
specification, replace thrust plate located between camshaft sprocket