Fuel 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 1113 of 1691
![DODGE RAM 1999 Service Repair Manual Lubricant
\
\
\
\
\
\](/img/12/56915/w960_56915-1112.png "DODGE RAM 1999 Service Repair Manual Lubricant
\
\
\
\
\
\")
Lubricant
\
\
\
\
\
\
\
Transfer Case NV241 HD 6.5 Pts. (3.1L)
Fluid
\
\
\
\
\
\
\
Power Take NV021 4.6 Pts. (2.1L)
Off Adapter
\
\
\
\
\
\
\
Power Drained 2.7 Pts. (1.3L)
Steering
Fluid
\
\
\
\
\
\
\
A/C Charge Capacity 32 Oz. (.9Kg)
Refrigerant
\
\
\
\
\
\
\
Refrigerant A/C System Capacity 7.75 Oz. (230ML)
Oil
\
\
\
\
\
\
\
Fuel Tank Capacity 35 Gal. (132L)
\
\
\
\
\
\
\
(
1) - Capacities are recommended or calculated levels. Always use
dipstick (if available) to measure level.
\f
\
\
\
\
\
\
\
MISCELLANEOUS NOTES
* Once a month, check tire pressure and look for unusual wear
or damage.
* Once a month, inspect battery and clean and tighten
terminals as required.
* Once a month, check fluid levels of coolant reservoir,
brake master cylinder, power steering & transmission.
Add fluids as required.
* Once a month, check all lights and all other electrical items
for correct operation
* Once a month, drain water from fuel filter.
* Once a month, check Filter Minder.
* Once a month, inspect and clean wiper blades as required.
Page 1174 of 1691
![DODGE RAM 1999 Service Repair Manual \
\
\
\
\
Model 286 (4WD) 10.1 Pts. (4.8L](/img/12/56915/w960_56915-1173.png "DODGE RAM 1999 Service Repair Manual \
\
\
\
\
Model 286 (4WD) 10.1 Pts. (4.8L")
\
\
\
\
\
Model 286 (4WD) 10.1 Pts. (4.8L)
\
\
\
\
\
\
\
Rear Axle Model 248 (2WD) 6.3 Pts. (3L)
Limited Slip
\
\
\
\
\
Differential Model 248 (4WD) 7.3 Pts. (3.4L)
\
\
\
\
\
Model 267 (2WD) 7 Pts. (3.3L)
\
\
\
\
\
Model 267 (4WD) 7.8 Pts. (3.6L)
\
\
\
\
\
Model 286 (2WD) 6.8 Pts. (3.2L)
\
\
\
\
\
Model 286 (4WD) 10.1 Pts. (4.8L)
\
\
\
\
\
\
\
Front Axle Model 216 6.8 Pts. (3.6L)
Lubricant
\
\
\
\
\
Model 248 7.6 Pts. (3.6L)
\
\
\
\
\
\
\
Transfer Case NV241 5 Pts. (2.7L)
Fluid
\
\
\
\
\
NV241 HD 6.5 Pts. (3.5L)
\
\
\
\
\
NV241 HD W/PTO 9 Pts. (4.9L)
\
\
\
\
\
\
\
Power Take NV021 4.6 Pts. (2.1L)
Off Adapter
\
\
\
\
\
\
\
Power Drained 2.7 Pts. (1.3L)
Steering
Fluid
\
\
\
\
\
\
\
A/C Charge Capacity 32 Oz. (.9Kg)
Refrigerant
\
\
\
\
\
\
\
Refrigerant A/C System Capacity 7.75 Oz. (230ML)
Oil
\
\
\
\
\
\
\
Fuel Tank 119" & 139" Wheelbase Vehicles 26 Gal. (98L)
\
\
\
\
\
All Others 35 Gal. (132L)
\
\
\
\
\
\
\
(
1) - Capacities are recommended or calculated levels. Always use
dipstick (if available) to measure level.
\f
\
\
\
\
\
\
\
MISCELLANEOUS NOTES
* Once a month, check tire pressure and look for unusual wear
or damage.
* Once a month, Inspect battery and clean and tighten
terminals as required.
* Once a month, check fluid levels of coolant reservoir,
brake master cylinder, power steering & transmission.
Add fluids as required.
* Once a month, check all lights and all other electrical items
for correct operation
* Once a month, Inspect and clean wiper blades as required.
* Twice a year, lubricate the external lock cylinders.
Page 1176 of 1691
![DODGE RAM 1999 Service Repair Manual 2.4L ........................................... 11.2 Qts. (10.6L)\
3.0L ........................................... 13.0 Qts. (12.3L)\
3.3L & 3.8L .................................... 1](/img/12/56915/w960_56915-1175.png "DODGE RAM 1999 Service Repair Manual 2.4L ........................................... 11.2 Qts. (10.6L)\
3.0L ........................................... 13.0 Qts. (12.3L)\
3.3L & 3.8L .................................... 1")
2.4L ........................................... 11.2 Qts. (10.6L)\
3.0L ........................................... 13.0 Qts. (12.3L)\
3.3L & 3.8L .................................... 13.2 Qts. (12.5L)\
Automatic Transaxle (Mopar ATF Plus Type 7176)
3-Speed
Drain & Refill .............................. (4) 4.0 Qts. (3.8L)
Dry Refill ...................................... 8.5 Qts. (8.0L)\
4-Speed
Drain & Refill .............................. ( 4) 4.0 Qts. (3.8L)
Dry Refill ...................................... 9.1 Qts. (8.6L)\
Overrunning Clutch
(Mopar ATF Plus Type 7176 - AWD Models) ...................... ( 5)
Power Steering Fluid ( 6) ............................ 1.7 Pts. (.8L)
Power Transfer Unit
(SAE 80W-90/API GL-5 - AWD Models) .............. 1.2 Qts. (1.14L\
)
Rear Differential
(SAE 80W-90/API GL-5 - AWD Models) ( 5) ....................... ( 7)
( 1) - Approximate quantity listed.
( 2) - Use an API energy conserving engine oil that is certified for
gasoline engines on all engines except 3.3L flex-fuel models.
On 3.3L flex-fuel models, use Mopar Flex-Fuel 5W-30 engine oil
or an equivalent that meets Chrysler Standard MS-9214. Proper
engine oil MUST BE used to prevent engine damage. The 3.3L
flex-fuel model may be referred to as Flex-Fuel Vehicle (FFV)
model and is used in all vehicles except California emission
vehicles. Flex-fuel model may be also referred to as an E85
application and may be identified by label attached to inside of
gasoline filler door.
( 3) - Quantity includes heater and coolant recovery tank. Add 2 qts.
(1.9L) if equipped with rear heater.
( 4) - Add this amount of fluid. Start engine and shift transaxle
through all gears and back to Park. Add additional fluid to
bring fluid level to 1/8" below the ADD mark on dipstick.
Recheck fluid level with transaxle at normal operating
temperature. Adjust fluid level so fluid level is within the
HOT range dipstick.
( 5) - An overrunning clutch is bolted on front of rear differential,
between torque tube for drive shaft and rear differential.
Overrunning clutch contains a separate reservoir from rear
differential. Ensure fluids are checked at appropriate
component, as different types of fluids are used. Fluid capacity
is not available from manufacturer.
( 6) - Use only Mopar power steering fluid. DO NOT use automatic
transmission fluid.
( 7) - Capacity is not available from manufacturer. Fill unit until
fluid level is even with bottom of filler plug hole.
\
\
\
\
\
\
\
FLUID CAPACITIES (DAKOTA) \
\
\
\
\
\
\
Application ( 1) Quantity
Crankcase (Includes Filter) ( 2)
2.5L ............................................. 4.5 Qts. (4.3L)\
3.9L ............................................. 4.0 Qts. (3.8L)\
5.2L & 5.9L ...................................... 5.0 Qts. (4.7L)\
Cooling System (Includes Heater)
2.5L ............................................. 9.8 Qts. (9.3L)\
3.9L ........................................... 14.0 Qts. (13.2L)\
5.2L & 5.9L .................................... 14.3 Qts. (13.5L)\
Automatic Transmission
(Mopar ATF Plus Type 7176)
Page 1181 of 1691
Severe Service (4) ............... ( 2) ................. 60,000
Coolant ............................. ( 5) .................... ( 5)
Drive Belt ........................... 48 ................. 60,000
Engine Oil
Normal Service ..................... 6 .................... 7500
Severe Service .................... ( 2) ................... 3000
Engine Oil Filter
Normal Service
2.4L .............................. 6 .................... 7500
All Others ........................ 12 ................. 15,000
Severe Service
2.4L ............................. ( 2) ................... 3000
All Others ....................... ( 2) ................... 6000
PCV Valve ( 4)
Normal Service ..................... 48 ................. 60,000
Severe Service .................... ( 2) ................. 30,000
Spark Plugs
2.4L & 3.0L
Normal Service .................... 24 ................. 30,000
Severe Service ................... ( 2) ................. 30,000
3.3L & 3.8L
Normal Service ................... ( 2) ................ 100,000
Severe Service ................... ( 2) ................. 75,000
Spark Plug Wires
2.4L & 3.0L
Normal Service .................... 48 ................. 60,000
Severe Service ................... ( 2) ................. 60,000
3.3L & 3.8L
Normal Service ................... ( 2) ................ 100,000
Severe Service ................... ( 2) ................. 75,000
Automatic Transaxle Fluid, Filter
& Band Adjustment ( 6)
Normal Service ..................... 24 ................. 30,000
Severe Service .................... ( 2) ................. 15,000
Power Transfer Unit Fluid
(AWD - Severe Service) ( 7) ......... ( 2) ................. 15,000
Rear Differential & Overrunning
Clutch Fluid/n
(AWD - Severe Service) ( 7) ........ ( 2) ................. 21,000
( 1) - Different interval may be required for normal and severe
service. Severe service is described as use of ethanol fuel,
frequent short trip operation of less than 5 miles, long periods
of engine idling, trailer towing, police, taxi, local delivery
service, or operating in dusty or excessively hot conditions.
( 2) - Monthly interval is not available from manufacturer.
( 3) - Inspect air filter every 15,000 miles and replace as necessary.
Replace at 30,000 miles unless previously replaced during
inspection.
( 4) - Inspect at scheduled interval and replace as necessary. Inspect
every 30,000 miles after first scheduled interval if not
previously replaced at scheduled interval listed.
( 5) - Replace coolant at 45,000 miles or 36 months whichever occurs
first. Replace coolant at 36 months regardless of mileage. After
first coolant change, replace coolant every 24 months or 30,000
miles thereafter.
( 6) - Band adjustment required on 3-speed automatic transaxle.
( 7) - Normal service interval is not available from manufacturer.
Manufacturer lists service schedule only under severe service
conditions.
\
\
\
\
\
\
\
REPLACEMENT INTERVALS (DAKOTA) ( 1)
Page 1187 of 1691
![DODGE RAM 1999 Service Repair Manual \
\
\
\
\
\
\
REPLACEMENT INTERVALS (RAM PICKUP - MEDIUM & H](/img/12/56915/w960_56915-1186.png "DODGE RAM 1999 Service Repair Manual \
\
\
\
\
\
\
REPLACEMENT INTERVALS (RAM PICKUP - MEDIUM & H")
\
\
\
\
\
\
\
REPLACEMENT INTERVALS (RAM PICKUP - MEDIUM & HEAVY DUTY - 5.9L
DIESEL) (1)
\
\
\
\
\
\
\
Component Months Miles
Air Filter ............................... ( 2) ............... ( 2)
Coolant .................................. ( 3) ............... ( 3)
Engine Oil & Filter
Normal Service .......................... 6 ............... 7500
Severe Service ......................... ( 4) .............. 3750
Fuel Filter
Normal Service .......................... 12 ............ 15,000
Severe Service ......................... ( 4) .............. 7500
Valve Clearance Adjustment ............... ( 5) ............... ( 5)
Automatic Transmission Fluid,
Filter & Band Adjustment
Normal Service .......................... 24 ............ 30,000
Severe Service ......................... ( 4) ............ 15,000
Manual Transmission Fluid ................ ( 6) ............... ( 6)
Transfer Case Fluid (4WD)
Normal Service .......................... 36 ............ 45,000
Severe Service ......................... ( 4) ............ 36,000
Front Differential Fluid (4WD) ( 7)
Severe Service ......................... ( 4) ............ 15,000
Rear Differential Fluid ( 7)
Severe Service ......................... ( 4) ............ 15,000
Repack Front Wheel Bearings (2WD)
Normal Service .......................... 24 ............ 30,000
Severe Service ......................... ( 4) ............ 30,000
Normal Service .......................... 48 ............ 48,000
Severe Service ......................... ( 4) ............ 48,000
( 1) - Different interval may be required for normal and severe
service. Severe service is described as long periods of engine
idling, frequent short trip operation of less than 5 miles,
trailer towing, off-highway operation, snow removal operation,
or operating in dusty or excessively hot conditions.
( 2) - Service interval is not available from manufacturer. Use filter-
minder on top of air cleaner housing to determine condition of
air filter. If filter-minder is in the Red zone, replace air
filter. Reset filter-minder by depressing button on top of
filter-minder.
( 3) - Replace coolant at 30,000 miles or 24 months whichever occurs
first. Replace coolant at 24 months regardless of mileage. After
first coolant change, replace coolant every 24 months or 30,000
miles thereafter.
( 4) - Monthly interval is not available from manufacturer.
( 5) - Does not require routine adjustments.
( 6) - Service interval is not available from manufacturer.
( 7) - Normal service interval is not available from manufacturer.
Manufacturer lists service schedule only under severe service
conditions.
\
\
\
\
\
\
\
REPLACEMENT INTERVALS (RAM VAN & RAM WAGON) ( 1) \
\
\
\
\
\
\
Component Months Miles
Air Filter
Normal Service ................... 24 ................... 30,000
Severe Service ................... ( 2) .............. ( 3) 15,000
Page 1198 of 1691
Fig. 8: Firing Order 8.0L V10 (Ram Pickup)
IGNITION TIMING
NOTE: On all models, ignition timing is controlled by Powertrain
Control Module (PCM). Ignition timing is non-adjustable. DO
NOT attempt to adjust ignition timing.
NOTE: On Dakota 3.9L, 5.2L and 5.9L, Durango, Ram Pickup 3.9L, 5.2L
and 5.9L (gasoline), Ram Van and Ram Wagon, the distributor
can be checked for proper location. See FUEL SYSTEM
SYNCHRONIZATION under FUEL SYSTEM in ON-VEHICLE ADJUSTMENTS.
FUEL SYSTEM
FUEL PUMP (GASOLINE)
FUEL PUMP PERFORMANCE \
\
\
\
\
\
\
Application Pressure psi Min. Vol.
(kg/cm) In 7 Sec. Pts. (L)
Page 1199 of 1691
Caravan
2.4L & 3.0L ............ (2) 43-53 (3.0-3.7) ............... ( 3)
3.3L
Flex-Fuel ............. ( 2) 50-60 (3.5-4.2) ............... ( 3)
Except Flex-Fuel ...... ( 2) 43-53 (3.0-3.7) ............... ( 3)
3.8L ................... ( 2) 43-53 (3.0-3.7) ............... ( 3)
Dakota & Durango ......... ( 1) 44-54 (3.0-3.8) ........... .5 (24)
Ram Pickup, Ram Van
& Ram Wagon ............. ( 1) 44-54 (3.0-3.8) ........... .5 (24)
Town & Country
3.3L
Flex-Fuel ............. ( 2) 50-60 (3.5-4.2) ............... ( 3)
Except Flex-Fuel ...... ( 2) 43-53 (3.0-3.7) ............... ( 3)
3.8L ................... ( 2) 43-53 (3.0-3.7) ............... ( 3)
Voyager
2.4L & 3.0L ............ ( 2) 43-53 (3.0-3.7) ............... ( 3)
3.3L
Flex-Fuel ............. ( 2) 50-60 (3.5-4.2) ............... ( 3)
Except Flex-Fuel ...... ( 2) 43-53 (3.0-3.7) ............... ( 3)
( 1) - Manufacturer lists fuel pressure with engine idling.
( 2) - Manufacturer lists fuel pressure with engine off, ignition on
and using scan tool to activate fuel pump.
( 3) - Information is not available from manufacturer.
\
\
\
\
\
\
\
FUEL INJECTION PUMP & FUEL TRANSFER PUMP (DIESEL)
NOTE: For fuel injection pump timing, see appropriate ON-VEHICLE
ADJUSTMENTS article.
FUEL INJECTION PUMP PERFORMANCE (DIESEL)
\
\
\
\
\
\
\
Application Output Pressure psi (kg/cm)
Ram Pickup 5.9L ................................................ ( 1)
( 1) - Pressure testing procedure and output pressure is not available
from manufacturer.
\
\
\
\
\
\
\
NOTE: For testing of fuel transfer pump, see appropriate BASIC
DIAGNOSTIC PROCEDURES article.
INJECTOR OPENING PRESSURE (DIESEL)
INJECTOR OPENING PRESSURE (DIESEL) \
\
\
\
\
\
\
Application psi (kg/cm)
Ram Pickup 5.9L ......................................... 4500 (316)\
\
\
\
\
\
\
\
INJECTOR RESISTANCE
INJECTOR RESISTANCE \
\
\
\
\
\
\
Application Ohms @ 68F (20C)
All Models ................................................... 10-16
\
\
\
\
\
\
\
Page 1210 of 1691
ON-VEHICLE TESTING
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.
DISABLING/ENABLING IGNITION & FUEL SYSTEMS
WARNING: To prevent engine from starting while performing tests,
always disable ignition and fuel systems.
Disabling Ignition & Fuel Systems
Remove Automatic Shutdown Relay (ASD) located in Power
Distribution Center (PDC). Refer to PDC cover for proper relay
location. PDC is located in engine compartment. On 5.9L diesel
engines, also disconnect fuel shutdown solenoid connector. Solenoid is
located behind upper intake manifold. See appropriate SYSTEM &
COMPONENT TESTING article in ENGINE PERFORMANCE section.
Enabling Ignition & Fuel Systems
When testing and/or repairs have been completed, verify
battery condition. Recharge battery as necessary, after starter tests
have been completed. Disconnect all test equipment. Install ASD relay.
On 5.9L diesel engines, reconnect fuel shutdown relay connector. On
all models, start engine several times to verify malfunction has been
corrected.
CRANKING TEST
NOTE: Ensure engine is at normal operating temperature. High
viscosity oil, extreme cold temperatures, or tight engine
will increase amperage draw.
1) Using a battery load tester, connect positive and negative
leads to battery. Connect inductive ammeter pick-up to positive
battery cable. Disable ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS.
2) Ensure all lights and accessories are off. Place A/T in
Park position or M/T in Neutral position. Apply parking brake. Crank
engine and observe voltmeter reading. If voltage is more than 9.6
volts and cranking amperage draw is more than specified amps, proceed
to CIRCUIT RESISTANCE TESTS. See STARTER SPECIFICATIONS - CARS or
STARTER SPECIFICATIONS - TRUCKS.
3) If voltage is 12.5 volts or more and cranking amperage
draw is less than specified, check starter circuit components in the
following order:
starter solenoid, starter relay, starter relay circuit, park/neutral
position switch or transmission range sensor (A/T), clutch pedal
position switch (M/T), ignition switch, wiring harness and
connections.
CIRCUIT RESISTANCE TESTS
NOTE: If excessive resistance is not found in circuits being
tested, remove starter and proceed to BENCH TESTING.
Battery Connection Resistance Test
1) Disable vehicle ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS. A voltmeter accurate to
one tenth of a volt will be needed for the following tests.
Page 1211 of 1691
2) Connect voltmeter positive lead to negative battery cable
clamp. Connect voltmeter negative lead to negative battery post. Crank
engine and observe voltmeter reading. If voltage is detected, repair
poor contact between cable clamp and post. Perform same procedure to
positive battery post and cable clamp.
Ground Connection Resistance Test
Connect voltmeter negative lead to negative battery post.
Connect voltmeter positive lead to engine block, near negative battery
cable grounding point. Crank engine and observe voltmeter reading. If
voltmeter reading indicates more than 0.2 volt, repair poor ground
connection or replace ground cable.
Starter Ground Connection Resistance Test
Connect voltmeter negative lead to negative battery post.
Connect voltmeter positive lead to starter housing. Crank engine and
observe voltmeter reading. If voltmeter reading indicates more than 0.
2 volt, repair poor starter-to-ground connection.
Positive Battery Cable Resistance Test
1) Remove starter heat shield (if equipped) to gain access t\
o
starter solenoid connections. Connect voltmeter negative lead to
starter solenoid battery terminal and voltmeter positive lead to
positive battery post.
2) Crank engine and observe voltmeter reading. If voltage
reads more than 0.2 volt, correct poor connection between battery
cable and starter solenoid or replace positive battery cable.
SOLENOID CIRCUIT TEST
NOTE: Perform SOLENOID CIRCUIT TEST before testing starter relay
and starter relay circuit. Ensure A/T is in Park position or
M/T is in Neutral position and parking brake is applied.
1) Disable vehicle ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS.
2) Ensure battery is fully charged. Ensure solenoid
connections are not loose or corroded. Remove starter relay from Power
Distribution Center (PDC). Refer to PDC cover for proper relay
location. PDC is located in engine compartment.
3) Connect a remote starter switch or jumper wire between
starter relay socket terminal No. 87 and positive battery post. See
Fig. 1 or 2. If engine cranks, solenoid and starter are good. Go to
STARTER RELAY TEST.
4) If engine fails to crank, or if solenoid chatters, check
wiring and connectors from starter relay socket to starter solenoid
terminal. Repair any loose or corroded connections. If engine still
fails to crank, remove starter and proceed to SOLENOID TEST under
BENCH TESTING.
STARTER RELAY TEST
NOTE: Perform SOLENOID CIRCUIT TEST before testing starter relay.
Remove starter relay from Power Distribution Center (PDC).
Refer to PDC cover for proper relay location. PDC is located in engine
compartment. Connect 12-volt power source to starter relay terminal
No. 86 and ground terminal No. 85. See Fig. 1 or 2. Using ohmmeter,
check continuity across starter relay terminals No. 30 and 87. If
continuity is not present, replace starter relay.
Page 1381 of 1691
Fig. 1: Locating Powertrain Control Module (PCM)
Courtesy of Chrysler Corp.
ENGINE SENSORS & SWITCHES
SENSORS
Battery Temperature Sensor
1) Battery temperature sensor is snapped into battery tray,
below driver's side battery. Disconnect wiring harness at battery
temperature sensor.
2) Using ohmmeter, check resistance between electrical
terminals on battery temperature sensor. Resistance should be 9000-11,
000 ohms at 75-80
F (25-27 C). Replace battery temperature sensor if
resistance is not within specification.
3) If problem exists in battery temperature sensor or wiring
circuit, a Diagnostic Trouble Code (DTC) will be stored in Powertrain
Control Module (PCM). See SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS
article.
Crankshaft Position Sensor
If problem exists in crankshaft position sensor, a Diagnostic
Trouble Code (DTC) will be stored in Powertrain Control Module (PCM)\
.
See appropriate crankshaft position sensor test in SELF-DIAGNOSTICS -
JEEP, TRUCKS & RWD VANS article.
Fuel Heater Temperature Sensor
See FUEL DELIVERY under FUEL SYSTEM.
Intake Manifold Air Temperature Sensor
Intake manifold air temperature sensor is located on top of
intake manifold, behind intake manifold air heater. For testing, see
DTC P0113: INTAKE AIR TEMPERATURE SENSOR VOLTAGE HIGH test in SELF-
DIAGNOSTICS - JEEP, TRUCKS & RWD VANS article.
Transmission Governor Pressure Sensor (A/T Models)