lock 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 929 of 1691
fitting and fuel lines are clean. Note location of release tab and
pull tab on disconnect fitting. See Fig. 6.
CAUTION: Release tab must be pressed downward before removing pull tab
or pull tab will be damaged.
2) Press release tab downward. Use screwdriver to pry pull
tab upward until pull tab separates from disconnect fitting. Remove
disconnect fitting from fuel line. Inspect components for damage. If
disconnect fitting is damaged, entire assembly must be replaced, as
only pull tab can be replaced.
3) To install, ensure fuel line and disconnect fitting are
clean. Lubricate fuel line and disconnect fitting with engine oil.
Install disconnect fitting on fuel line until disconnect fitting
bottoms on fuel line.
4) Install NEW pull tab until pull tab locks in disconnect
fitting. DO NOT reuse old pull tab. Pull on fuel line and disconnect
fitting to ensure components are properly locked together. Reconnect
negative battery cables. Start engine and check for leaks.
Removal & Installation (Dual Tab)
1) Disconnect negative battery cables. Ensure disconnect
fitting and fuel lines are clean. Note location of tabs on disconnect
fitting. See Fig. 6.
2) Squeeze both tabs against disconnect fitting. Pull
disconnect fitting from fuel line. The plastic retainer will remain on
the fuel system component being serviced. The "O" rings and spacer
will remain in the disconnect fitting.
3) Inspect components for damage. If disconnect fitting is
damaged, entire assembly must be replaced. The only component that may
be replaced is the plastic retainer. If plastic retainer must be
removed from fuel system component, carefully release the plastic
retainer from the fuel system component using 2 screwdrivers. Inspect
plastic retainer for cracks or damage. Replace plastic retainer if
defective.
4) To install, ensure fuel line and disconnect fitting are
clean. Lubricate fuel line and disconnect fitting with engine oil.
Install disconnect fitting on fuel line until click sound is heard.
5) Pull on fuel line and disconnect fitting to ensure
components are properly locked together. Reconnect negative battery
cables. Start engine and check for leaks.
Removal & Installation (Plastic Retainer Ring)
1) Disconnect negative battery cables. Ensure disconnect
fitting and fuel lines are clean. Note location of plastic retainer
ring on disconnect fitting. See Fig. 6.
NOTE: Plastic retainer ring must be pressed evenly into disconnect
fitting. If plastic retainer is not even, it will be
difficult to remove disconnect fitting from fuel line.
2) Firmly push disconnect fitting toward the fuel line while
pushing plastic retainer ring evenly into disconnect fitting. With
plastic retainer ring fully depressed, pull disconnect fitting from
fuel line.
3) Inspect components for damage. If disconnect fitting is
damaged, entire assembly must be replaced.
4) To install, ensure fuel line and disconnect fitting are
clean. Lubricate fuel line and disconnect fitting with engine oil.
Install disconnect fitting on fuel line until click sound is heard.
5) Pull on fuel line and disconnect fitting to ensure
components are properly locked together. Reconnect negative battery
cables. Start engine and check for leaks.
Page 932 of 1691
Removal
1) Raise and support vehicle. Disconnect negative battery
cables. Drain fuel tank. Remove fuel tank filler tube bolts from body.
Support fuel tank with transmission jack. Remove fuel tank straps and
heat shields (if equipped).
2) Slightly lower fuel tank for access to fuel lines and
electrical connector at fuel tank module. Disconnect electrical
connector and fuel lines at fuel tank module. See Fig. 7. Use proper
procedure when disconnecting fuel lines. See FUEL LINE DISCONNECT
FITTINGS under FUEL SYSTEM.
NOTE: Information for servicing of in-tank fuel filter is not
available from manufacturer. If necessary to service in-tank
fuel filter, consult parts department to verify if filter may
be replace without replacing fuel tank module.
3) Note direction of fuel line connections on fuel tank
module for installation reference. Using Spanner Wrench (6856),
unscrew plastic fuel tank module lock nut from fuel tank. Remove fuel
tank module and gasket from fuel tank. Inspect in-tank fuel filter for
damage.
Installation
1) Using NEW gasket, install fuel tank module in fuel tank.
Install plastic fuel tank module lock nut finger tight. DO NOT tighten
plastic fuel tank module lock nut at this time.
2) Position fuel tank module so fuel line connections and
electric connection are facing toward driver's side of vehicle. This
must be done to prevent float on fuel gauge sending unit from
contacting fuel tank.
3) Once fuel tank module is properly positioned, tighten
plastic fuel tank module lock nut to specification. See TORQUE
SPECIFICATIONS.
4) Install fuel lines on fuel tank module using proper
procedure. See FUEL LINE DISCONNECT FITTINGS under FUEL SYSTEM.
Install electrical connector on fuel tank module. Reinstall fuel tank.
Tighten fuel tank strap nuts to specification. See TORQUE
SPECIFICATIONS. Reconnect negative battery cables.
Fig. 7: Locating Fuel Tank Module & Fuel Tank Rollover Valve
Courtesy of Chrysler Corp.
FUEL INJECTOR DRAIN LINE ASSEMBLY
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Apply light coat of engine oil on NEW .060" (1.5 mm) thick Copper
sealing washer. Install NEW Copper sealing washer on spray tip of fuel
injector. Engine oil is used to aid holding sealing washer in place.
Install new "O" ring on fuel injector. Apply small amount of engine
oil to "O" ring.
2) Ensure fuel inlet hole on side of fuel injector is
positioned toward injector connector tube. Install injector into
cylinder head bore using care not to allow injector tip to touch sides
of bore. Press fuel injector into cylinder head with finger pressure
only. Install fuel injector hold down clamp into shouldered bolt while
aligning slot in top of injector into groove in bottom of clamp.
Tighten opposite clamp bolt to specification. See TORQUE
SPECIFICATIONS.
3) Apply small amount of clean engine oil to NEW "O" ring.
Install "O" ring to fuel injector connector tube. Using finger
pressure only, press injector connector tube into cylinder head.
Connect and tighten high pressure fuel lines to specification. See
TORQUE SPECIFICATIONS.
NOTE: Fuel line fitting torque is important. Mating surfaces will
not seal if fuel line fitting is under or over-torqued.
4) To install remaining components, reverse removal
procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Bleed high-pressure fuel lines. See FUEL LINE BLEEDING under FUEL
SYSTEM.
FUEL INJECTION PUMP
CAUTION: High-pressure fuel lines must be clamped securely and routed
so they do not contact each other or any other components. DO
NOT weld or substitute high-pressure fuel lines. High
-pressure lines are same length and proper high-pressure fuel
line must be installed in specified area for proper engine
operation.
Removal
1) Disconnect negative battery cables. Clean fuel lines at
cylinder head and injection pump. Clean fuel injection pump and fuel
lines at side of pump. Disconnect 9-pin electrical connector at Fuel
Pump Control Module (FPCM). Place a rag around overflow valve to catch\
excess fuel. Remove overflow valve and disconnect fuel return line.
Remove banjo bolts and fuel supply line at side of injection pump and
top of fuel filter housing.
2) Remove all high pressure fuel lines, intake air tube,
accelerator pedal position sensor, air intake housing, engine oil
dipstick tube, wiring clips, electrical connectors at intake heaters,
and engine lifting bracket. Unscrew plastic access cap at front gear
cover. Remove injection pump gear-to-injection pump shaft nut and
washer.
3) Engine may be rotated by removing dust plug from
transmission adapter plate and installing Engine Barring Tool (Snap-On
SP371) in transmission adapter plate. See Fig. 9. Rotate engine until
keyway is at 12 o'clock position.
Page 935 of 1691
Fig. 9: Rotating Engine
Courtesy of Chrysler Corp.
CAUTION: Engine must be rotated until keyway is at 12 o'clock position
to prevent pump/gear keyway from falling into gear housing.
If gear retainer nut, washer or key drops into gear housing,
cover may have to be removed to retrieve them before engine
start.
4) Using gear puller, separate injection pump gear from
injection pump shaft. See Fig. 11. DO NOT pull fuel injection pump
drive gear too far forward or timing gear cover may be damaged.
5) Remove 3 lower fuel injection pump-to-lower mounting
bracket bolts. Loosen 2 engine bracket bolts. See Fig. 10. Remove 4
fuel injection pump-to-gear housing nuts. Remove fuel injection pump.
Use care not to scratch or damage shaft of fuel injection pump during
removal.
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INTAKE MANIFOLD AIR HEATER
Removal & Installation
1) Disconnect negative battery cables. Disconnect clamp and
rubber hose at air intake housing. Remove engine oil dipstick tube
mounting bolt and position dipstick tube aside. Disconnect heater
electrical cables at cable mounting studs. Remove 4 air intake housing
bolts. Remove air intake housing from top of intake manifold air
heater elements. See Fig. 13.
2) Remove heater element assembly from intake manifold. Clean
old gasket from air intake housing, intake manifold, and both sides of
engine block. To install, reverse removal procedure using NEW gaskets.
Tighten all bolts to specification. See TORQUE SPECIFICATIONS.
Fig. 13: Removing Intake Manifold Air Heater
Courtesy of Chrysler Corp.
INTAKE MANIFOLD AIR HEATER RELAYS
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![DODGE RAM 1999 Service Repair Manual Removal & Installation
See INTAKE MANIFOLD AIR HEATER RELAYS under RELAYS &
SOLENOIDS.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
\](/img/12/56915/w960_56915-940.png "DODGE RAM 1999 Service Repair Manual Removal & Installation
See INTAKE MANIFOLD AIR HEATER RELAYS under RELAYS &
SOLENOIDS.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Removal & Installation
See INTAKE MANIFOLD AIR HEATER RELAYS under RELAYS &
SOLENOIDS.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)\
Access Plug ................................................ 11 (15)\
AFC Line-To-Fuel Injection Pump Fitting .................... 18 (24)\
Air Inlet Housing Bolt ..................................... 18 (24)\
Engine Bracket-To-Engine Bolts ............................. 18 (24)\
Engine Coolant Temperature Sensor .......................... 40 (54)\
Engine Speed Sensor Nut .................................... 18 (24)\
Fuel Injection Pump Drive Gear Nut ....................... 125 (170)\
Fuel Injection Pump Lower Bracket-To-Pump Bolts ............ 18 (24)\
Fuel Injection Pump Mount Nuts ............................. 32 (43)\
Fuel Injector Retaining Nut ................................ 44 (60)\
Fuel Line-To-Fuel Heater Fitting ........................... 18 (24)\
Fuel Line-To-Fuel Transfer Pump ............................ 18 (24)\
Fuel Supply Line Banjo Bolt ................................ 18 (24)\
Fuel Tank Strap Nut ........................................ 30 (41)\
Fuel Transfer Pump Bolt .................................... 18 (24)\
High-Pressure Fuel Line Clamp Bolt ......................... 18 (24)\
High-Pressure Fuel Line Nut (At Injector) .................. 28 (38\
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High-Pressure Fuel Line Nut (At Pump) ...................... 18 (24\
)
Intake Manifold Air Heater Housing Bolt .................... 18 (24)\
Intake Manifold Air Temperature Sensor ..................... 20 (27)\
Intake Manifold Cover Bolt ( 1) ............................. 18 (24)
Oil Fill Plug .............................................. 21 (29)\
Overflow Valve-To-Fuel Injection Pump ...................... 24 (33)\
Park/Neutral Switch ........................................ 25 (34)\
Plastic Fuel Tank Module Lock Nut .......................... 32 (43)\
Starter Mounting Bolt ...................................... 32 (43)\
Turbocharger Oil Drain Line Bolt ........................... 18 (24)\
Turbocharger Oil Supply Line Nut ........................... 11 (15)\
Turbocharger Retaining Nut ................................. 24 (33)\
INCH Lbs. (N.m)
Air Inlet Tube-To-Turbocharger Clamp Nut .................. 72 (8.1)\
Canister Nut ............................................ 120 (13.6)\
Condenser-To-Intercooler Nut ............................. 95 (10.7)\
Condenser-To-Intercooler Screw ........................... 95 (10.7)\
Drain Valve-To-Canister Bolt .............................. 40 (4.5)\
Exhaust Pipe-To-Turbocharger Clamp Nut .................... 72 (8.1)\
Fuel Bleed Bolt ........................................... 72 (8.1)\
Fuel Injector Drain Line Assembly Retaining Clamp Bolt .. 120 (13.6)\
Fuel Injector Drain Line-To-Fuel Injector Banjo Bolt ...... 84 (9.5)\
Intake Manifold Air Heater Relay Assembly Retaining Bolt .. 40 (4.5)\
Intercooler Bolt .......................................... 17 (1.9)\
Intercooler Inlet & Outlet Duct Clamp ..................... 72 (8.1)\
PCM Mounting Bolt ......................................... 35 (4.0)\
Water-In-Fuel (WIF) Sensor ................................ 20 (2.3\
)
( 1) - Apply thread sealant to bolt threads.
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N - R EM OVE/IN STA LL/O VER HAU L - R W D - G ASO LIN E
1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Removal, Overhaul & Installation - Gasoline
Dakota, Durango, Ram Pickup, Ram Van, Ram Wagon
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.
INTRODUCTION
Removal, overhaul and installation procedures are covered in
this article. If component removal and installation is basically an
unbolt and bolt-on procedure, only a torque specification may be
provided.
COMPUTERIZED ENGINE CONTROLS
POWERTRAIN CONTROL MODULE (PCM)
NOTE: If replacing Powertrain Control Module (PCM), the correct
vehicle mileage and Vehicle Identification Number (VIN) must
be programmed into the PCM to prevent Diagnostic Trouble
Codes (DTCs) from being set in the Anti-Lock Brake System
(ABS) module and Supplemental Restraint System (SRS) module\
.
To program PCM and clear DTCs from ABS and SRS modules, see
PCM PROGRAMMING. If replacing Powertrain Control Module (PCM)\
on models equipped with a Smart Key Immobilizer Module
(SKIM), the secret key data must also be updated to enable
engine starting. To update secret key data, see PCM
PROGRAMMING.
Removal & Installation
1) PCM is located in the engine compartment. See Figs. 1-3.
Disconnect negative battery cable. Remove cover for access to
electrical connectors at PCM. Disconnect electrical connectors from
PCM. Remove PCM retaining bolts and PCM.
2) To install, reverse removal procedure. Tighten PCM
retaining bolts to specification. See TORQUE SPECIFICATIONS.
Fig. 1: Locating PCM (Dakota & Durango)
Courtesy of Chrysler Corp.
Page 944 of 1691
Procedure For Programming PCM & Clearing DTCs From ABS & SRS
Modules
Connect scan tool to Data Link Connector (DLC). DLC is
located under left side of instrument panel. Using scan tool, enter
correct VIN and mileage into PCM. Using scan tool manufacturer's
instructions, clear DTCs from ABS and SRS modules.
Procedure For Updating Secret Key Data
1) Connect scan tool to Data Link Connector (DLC). DLC is
located under left side of instrument panel.
2) Go to ENGINE and then MISC menus on scan tool. Place the
SKIM in SECURED ACCESS MODE by using the appropriate Personal
Identification Number (PIN) for this vehicle. PIN may be obtained from\
the owner, vehicle's invoice, or from the manufacturer. Select UPDATE
THE SECRET KEY DATA. The data will be transferred from Smart Key
Immobilizer Module (SKIM) to the PCM, allowing the vehicle to start.
NOTE: On Ram Van and Ram Wagon, if 3 attempts are made to enter the
SECURED ACCESS MODE using the incorrect Personal
Identification Number (PIN), the SECURED ACCESS MODE will be
locked out for one hour. To exit this locked out mode, leave
ignition switch in the ON position for one hour with all
accessories turned off. It may be necessary to monitor
battery state and connect a battery charger if necessary.
ENGINE SENSORS & SWITCHES
BATTERY TEMPERATURE SENSOR
Removal & Installation
Battery temperature sensor is snapped into center of battery
tray, directly below the battery. Remove battery. Disconnect
electrical connector for battery temperature sensor. Pry battery
temperature sensor straight upward from battery tray. To install,
reverse removal procedure.
BRAKE SWITCH
NOTE: Brake switch may also be referred to as brakelight switch or
stoplight switch.
Removal (Dakota, Durango & Ram Pickup)
1) Brake switch is located near top of brake pedal. Remove
lower instrument panel cover for access to brake switch if necessary.
Disconnect electrical connector from brake switch. Depress and hold
brake pedal downward.
2) Rotate brake switch counterclockwise approximately 30
degrees so alignment tab on brake switch aligns with opening on
mounting bracket. Pull brake switch rearward from mounting bracket.
NOTE: Before installing brake switch, plunger on brake switch must
be pulled outward to fully extended position and then pushed
inward 4 detent positions to ensure proper brake switch
adjustment.
Installation
1) Pull plunger on brake switch outward to the fully extended
position. Push plunger on brake switch inward 4 detent positions. The
brake switch will click at each detent position when pushing plunger
inward.
2) Install electrical connector on brake switch. Depress
brake pedal as far as possible. Install brake switch in mounting
Page 945 of 1691
bracket. Ensure alignment tab on brake switch aligns with opening on
mounting bracket.
CAUTION: When adjusting brake switch, DO NOT pull brake pedal back
toward brake switch with excessive pressure, or brake switch
may be damaged.
3) When brake switch is fully installed in mounting bracket,
rotate brake switch clockwise approximately 30 degrees. To ensure
proper brake switch adjustment, gently pull brake pedal back toward
brake switch as far as possible. DO NOT apply excessive pressure on
brake pedal and brake switch.
Removal (Ram Van & Ram Wagon)
1) Brake switch is located near top of brake pedal. Remove
lower steering column cover. Remove data link connector, hood release
lever and parking brake lever from lower instrument panel cover.
2) Remove lower instrument panel cover for access to brake
switch. Depress and hold brake pedal downward. Rotate brake switch
counterclockwise approximately 1/16 turn to so locking collar on brake
switch aligns with opening on mounting bracket. Pull brake switch
rearward from mounting bracket. Disconnect electrical connector from
brake switch.
NOTE: Before installing brake switch, plunger on brake switch must
be pulled outward to fully extended position and then pushed
inward 4 detent positions to ensure proper brake switch
adjustment.
Installation
1) Pull plunger on brake switch outward to the fully extended
position. Push plunger on brake switch inward 4 detent positions. The
brake switch will click at each detent position when pushing plunger
inward.
2) Install electrical connector on brake switch. Depress
brake pedal as far as possible. Install brake switch in mounting
bracket. Ensure locking collar on brake switch aligns with opening on
mounting bracket.
CAUTION: When adjusting brake switch, DO NOT pull brake pedal back
toward brake switch with excessive pressure, or brake switch
may be damaged.
3) When brake switch is fully installed in mounting bracket,
rotate brake switch clockwise approximately 1/16 turn. To ensure
proper brake switch adjustment, gently pull brake pedal back toward
brake switch as far as possible. DO NOT apply excessive pressure on
brake pedal and brake switch.
CAMSHAFT POSITION SENSOR
Removal & Installation
See CAMSHAFT POSITION SENSOR under IGNITION SYSTEM.
CRANKSHAFT POSITION SENSOR
Removal & Installation
See CRANKSHAFT POSITION SENSOR under IGNITION SYSTEM.
DOWNSTREAM OXYGEN SENSOR
NOTE: Downstream oxygen sensor may also be referred to as post
-catalyst oxygen sensor.
Page 951 of 1691
NOTE: Oil pressure sensor may also be referred to as engine oil
pressure sensor.
Removal & Installation
For oil pressure sensor location, see OIL PRESSURE SENSOR
LOCATION table. Service information is not available from
manufacturer.
OIL PRESSURE SENSOR LOCATION
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Application Location
Dakota
2.5L ... ( 1) Passenger's Side Of Cylinder Block, Below Distributor
3.9L, 5.2L & 5.9L ... ( 1) Passenger's Side Rear Corner Of Cylinder
Block, Below Distributor
Durango .. ( 1) Passenger's Side Rear Corner Of Cylinder Block, Below
Distributor
Ram Pickup
3.9L, 5.2L & 5.9L ... ( 2) Passenger's Side Rear Corner Of Cylinder
Block, Below Distributor
8.0L ......................................... ( 2) Near Oil Filter
Ram Van & Ram Wagon ... ( 3) Passenger's Side Rear Corner Of Cylinder
Block, Below Distributor
( 1) - Contains a Gray/Yellow wire and a Black/Light Blue wire in the
electrical connector.
( 2) - Contains a Gray/Orange wire and a Black/Light Blue wire in the
electrical connector.
( 3) - Contains a Gray wire and a Black/Light Blue wire in the
electrical connector.
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OUTPUT SHAFT SPEED SENSOR
NOTE: Output shaft speed sensor may also be referred to as
transmission speed sensor.
Removal & Installation (A/T Models)
Output shaft speed sensor is located on lower edge of
overdrive case on rear of transmission. See Fig. 10. Disconnect
electrical connector at output shaft speed sensor. Remove output shaft
speed sensor with "O" ring from transmission. To install, reverse
removal procedure using NEW "O" ring.
Fig. 10: Locating Output Shaft Speed Sensor & Park/Neutral Switch
(A/T)
Courtesy of Chrysler Corp.
PARK/NEUTRAL SWITCH