air filter DODGE RAM 1999 Service Owner's Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 470 of 1691
* D RIV ETR AIN S YSTE M S U NIF O RM IN SPEC TIO N G UID ELIN ES *
1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
Drivetrain/Transmission Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Drive/Power Train Assemblies
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES
DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES
TRANSFER CASE ASSEMBLIES
Drive/Power Train Components
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
AXLES
BEARINGS AND RACES
BELL CRANKS
BELL HOUSINGS
BUSHINGS (EXTERNAL)
CABLES (SPEEDOMETER)
CABLES (TV, DETENT AND SHIFT)
CARRIER BEARINGS
CLUTCH CABLES AND CABLE HOUSINGS
CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH FORKS
CLUTCH LINKAGES (MECHANICAL)
CLUTCH MASTER CYLINDERS
CLUTCH PEDALS
CLUTCH PIVOTS
CLUTCH PRESSURE PLATES
CLUTCH RELEASE BEARINGS
CLUTCH SLAVE CYLINDERS (CONCENTRIC)
CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)
COMPANION FLANGES
CONNECTORS
COOLER BYPASS VALVES
COOLER LINES
COOLERS
CV JOINTS
DIP STICK TUBES
DIP STICKS (FLUID LEVEL INDICATORS)
DOWEL PINS, GUIDES AND PILOT HOLES
DRIVE SHAFT FLANGES
DRIVE SHAFTS AND HALF SHAFTS
DUST BOOTS
ENGINE MOUNTS
EXCITER RINGS
FILLER TUBES
FILTERS AND SCREENS
Page 490 of 1691
![DODGE RAM 1999 Service Owners Manual Torn .................... A ............ Require replacement. \
\
\
\
\
\](/img/12/56915/w960_56915-489.png "DODGE RAM 1999 Service Owners Manual Torn .................... A ............ Require replacement. \
\
\
\
\
\")
Torn .................... A ............ Require replacement. \
\
\
\
\
\
\
ENGINE MOUNTS
See MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION) .
EXCITER RINGS
See TOOTHED RINGS (TONE WHEELS) .
FILLER TUBES
See DIP STICK TUBES .
FILTERS AND SCREENS
FILTER AND SCREEN INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
At service interval ..... 3 ............ Suggest replacement.
Bent .................... A .. Require repair or replacement.
Exceeding service
interval ............... 3 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Near service interval ... 3 ............ Suggest replacement.
Restricted .............. A ........... ( 1) Require repair or
replacement.
Torn .................... A ............ Require replacement.
Worn, affecting
performance (metal or
nylon screen type) ..... A .. Require repair or replacement.
( 1) - Further inspection may be required to determine the
source of restriction or contamination.
\
\
\
\
\
\
\
FLANGES
See COMPANION FLANGES .
FLEX PLATES
FLEX PLATE INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Bent, affecting
performance ............ A ............ Require replacement.
Bent, not affecting
performance ............ .. ........ No service suggested or
required.
Bolt or stud holes
elongated .............. B ............ Require replacement.
Broken .................. A ............ Require replacement.
Cracked ................. A ............ Require replacement.
Ring gear worn close
to the end of its
useful life ............ 1 ............ Suggest replacement.
Ring gear worn to the
extent that it no longer
Page 498 of 1691
Scored .................. B ............ Require replacement.
Spring rate less than
specifications ......... B ............ Require replacement.
Worn, affecting
performance ............ A ............ Require replacement.
Worn beyond
specifications ......... B ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
\
\
\
\
\
\
\
PRESSURE SWITCHES
See SWITCHES.
RACES
See BEARINGS AND RACES .
RUBBER JOINTS (METALASTIC)
These joints may be found on half and/or drive shafts. They
are usually found on European vehicles featuring a three-lug drive
flange. They may be equipped with a centering ball or pin.
RUBBER JOINT (METALASTIC) INSPECTION
\
\
\
\
\
\
\
Condition Code Procedure
Drive flange bent ....... A ............. Require repair or
replacement.
Drive flange damaged,
affecting performance .. A ............ Require replacement.
Rubber drive joint
cracked ................ 2 ............ Suggest replacement.
Rubber drive joint
damaged, affecting
performance ............ A ............ Require replacement.
Rubber drive joint split
between mounting holes . A ............ Require replacement.
Rubber drive joint torn at
mounting holes ......... A ............ Require replacement.
Rubber drive joint weather-
cracked ................ .. ........ No service suggested or
required.
\
\
\
\
\
\
\
SCREENS
See FILTERS AND SCREENS .
SEALS
SEAL INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Leaking ................. A ........... ( 1) Require repair or
replacement.
( 1) - Require inspection of mating and sealing surface and
repair or replace as necessary. Check vent. A plugged
Page 506 of 1691
performance ............ A .. Require repair or replacement.
Fins damaged, not
affecting performance .. .. ........ No service suggested or
required.
Internal restrictions ... B .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A .. Require repair or replacement.
Tubes damaged, affecting
performance ............ A .. Require repair or replacement.
Tubes damaged, not
affecting performance .. .. ........ No service suggested or
required.
\
\
\
\
\
\
\
TRANSMISSION MOUNTS
See MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION) .
TRANSMISSION PANS
TRANSMISSION PAN INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Bent, interfering with
filter or other internal
components ............. A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
\
\
\
\
\
\
\
TRANSMISSION RANGE INDICATORS (PRNDL)
TRANSMISSION RANGE INDICATOR (PRNDL) INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Binding ................. A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Components missing ...... C .. Require replacement of missing
components.
Loose, affecting
performance ............ A .. Require repair or replacement.
Out of adjustment ....... A ................. Require repair.
Worn, affecting
performance ............ A .. Require repair or replacement.
\
\
\
\
\
\
\
TUBES
See HOSES, LINES AND TUBES .
UNIVERSAL JOINTS (CARDON OR CROSS TYPE)
UNIVERSAL JOINT (CARDON OR CROSS TYPE) INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Page 512 of 1691
![DODGE RAM 1999 Service Owners Manual CIRCUIT PROTECTION DEVICES
\
\
\
\
\
\
\
Component](/img/12/56915/w960_56915-511.png "DODGE RAM 1999 Service Owners Manual CIRCUIT PROTECTION DEVICES
\
\
\
\
\
\
\
Component")
CIRCUIT PROTECTION DEVICES
\
\
\
\
\
\
\
Component Component Location \
\
\
\
\
\
\
Circuit Breakers In junction block.
Junction Block Left end of dash.
Power Distribution Center In engine compartment, on left
inner fender panel, near
battery.
\
\
\
\
\
\
\
CONTROL UNITS
\
\
\
\
\
\
\
Component Component Location \
\
\
\
\
\
\
Air Bag Control Module Behind lower center of dash.
Controller Anti-Lock Brake (4WABS) Engine compartment, mounted on\
top of hydraulic control unit.
Controller Anti-Lock Brake (RWAL) In engine compartment, on left\
front inner fender.
Daytime Running Lamp (DRL) Module In engine compartment, on left\
inner fender panel.
Engine Control Module (Diesel) On left side of engine, behind\
fuel filter.
Fuel Pump Module Top of fuel tank.
Integrated Electronic Module Left side of dash, inboard of
steering column opening.
Powertrain Control Module (PCM) In engine compartment, on
right side of firewall.
Seat Belt Control Module Under front seat center
cushion.
\
\
\
\
\
\
\
MOTORS
\
\
\
\
\
\
\
Component Component Location \
\
\
\
\
\
\
Blower Motor Behind right side of dash.
Fuel Injection Pump (Diesel) On left side of engine, on
rear of timing gear housing.
Fuel Transfer Pump (Diesel) On left side of engine, below
and rearward of fuel filter.
Page 598 of 1691
(8) - One used on vehicles with light-duty emissions. Two used on
vehicles with heavy-duty emissions.
(
9) - Used on vehicles with heavy-duty emissions.
(
10 ) - Two catalytic converters are required.
(
11 ) - Four sensors used on vehicles with medium-duty emissions.
Two sensors used on vehicles with heavy-duty emissions.
\
\
\
\
\
\
\
\f
ABBREVIATIONS
ABBREVIATION DEFINITIONS\
\
\
\
\
\
Abbreviation Definition
AIH ................................... Air Intake Heaters
AIH-TS ............................ AIH Temperature Sensor
AP ............................. Air Pump Injection System
AP-CKV .................................... AP Check Valve
AP-RV .................................... AP Relief Valve
BP/EGR ........................... Backpressure EGR System
BP/EGR-BPT ................ BP/EGR Backpressure Transducer
CCV ................................ Crankcase Ventilation
CEC ......................... Computerized Engine Controls
CNG ............................... Compressed Natural Gas
EFI ............................ Electronic Fuel Injection
EGR-CKV .................................. EGR Check Valve
EVAP ............................. Fuel Evaporative System
EVAP-CVV ........................ EVAP Canister Vent Valve
EVAP-LDP ........................ EVAP Leak Detection Pump
EVAP-LDPF ................ EVAP Leak Detection Pump Filter
EVAP-PRRV ............ EVAP Pressure Relief Rollover Valve
EVAP-PSOL ............................ EVAP Purge Solenoid
EVAP-VC .............................. EVAP Vapor Canister
EVAP-VV ........................... EVAP Ventilation Valve
FR ................................... Fillpipe Restrictor
HO2S ................................ Heated Oxygen Sensor
MIL .......................... Malfunction Indicator Light
PCV ....................... Positive Crankcase Ventilation
SFI .................. Sequential Multiport Fuel Injection
SPK ....................................... Spark Controls
SPK-CC ........................... SPK Computer Controlled
TWC ........................ Three-Way Catalytic Converter
\
\
\
\
\
\
Page 603 of 1691
inspection procedures.
A visual inspection is made to determine if any required
emission control devices are missing, modified or disconnected.
Missing, modified or disconnected systems must be made fully
operational before a vehicle can be certified.
POSITIVE CRANKCASE VENTILATION (PCV)
PCV controls the flow of crankcase fumes into the intake
manifold while preventing gases and flames from traveling in the
opposite direction. PCV is either an open or closed system. See Fig. 2
.
Ensure PCV system is installed as required. Verify valve,
required hoses, connections, flame arresters, etc., are present,
routed properly and in serviceable condition.
Fig. 2: Typical Open & Closed Type PCV System
THERMOSTATIC AIR CLEANER (TAC)
The TAC supplies warm air to air intake during cold engine
operation. This system is active during cold engine warm-up only.
Under all other operating conditions, air cleaner function is the same
as any non-thermostatic unit.
Ensure required exhaust shroud, hot air duct, vacuum hoses
and air cleaner components are present and installed properly. See
Fig. 3 . Ensure any required thermostatic vacuum switches are in place
and vacuum hoses are installed and in serviceable condition. Also
ensure air cleaner lid is installed right side up. Check for oversized
air filter elements and for additional holes in the air cleaner
housing.
Page 613 of 1691
Spark control systems are designed to ensure the air/fuel
mixture is ignited at the best possible moment to provide optimum
efficiency and power and cleaner emissions.
Ensure vacuum hoses to the distributor, carburetor, spark
delay valves, thermal vacuum switches, etc., are in place and routed
properly. On Computerized Engine Controls (CEC), check for presence of\
required sensors (O2, MAP, CTS, TPS, etc.). Ensure they have not been
tampered with or modified.
Check for visible modification or replacement of the feedback
carburetor, fuel injection unit or injector(s) with a non-feedback
carburetor or fuel injection system. Check for modified emission-
related components unacceptable for use on pollution-controlled
vehicles.
AIR INJECTION SYSTEM (AIS)
Air Pump Injection System (AP)
The air pump is a belt-driven vane type pump, mounted to
engine in combination with other accessories. The air pump itself
consists of the pump housing, an inner air cavity, a rotor and a vane
assembly. As the vanes turn in the housing, filtered air is drawn in
through the intake port and pushed out through the exhaust port. See
Fig. 13 .
Check for missing or disconnected belt, check valve(s),
diverter valve(s), air distribution manifolds, etc. Check air
injection system for proper hose routing.
Fig. 13: Typical Air Pump Injection System
Courtesy of General Motors Corp.
Pulsed Secondary Air Injection (PAIR) System
PAIR eliminates the need for an air pump and most of the
associated hardware. Most systems consists of air delivery pipe(s),
pulse valve(s) and check valve(s). The check valve prevents exhaust
gases from entering the air injection system. See Fig. 14.
Ensure required check valve(s), diverter valve(s), air
distribution manifolds, etc., are present. Check air injection system
for proper hose routing.
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 704 of 1691
* E N G IN E S YSTE M S U NIF O RM IN SPEC TIO N G UID ELIN ES *
1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
Engine Performance and Maintenance Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
Engine Assemblies
CYLINDER HEAD ASSEMBLIES
LONG BLOCK ASSEMBLIES
SHORT BLOCK ASSEMBLIES
Engine Components
ACCELERATOR PEDAL POSITION SENSORS
ACCESSORY BELTS
ACCESSORY PULLEYS
ACTUATORS
AIR CONDITIONING CYCLING SWITCHES
AIR CONDITIONING PRESSURE SENSORS
AIR DUCTS AND TUBES
AIR FILTER ELEMENTS
AIR FILTER GASKETS
AIR FILTER HOUSINGS AND GASKETS
AIR FUEL RATIO SENSORS
AIR INJECTION CONTROL SOLENOIDS
AIR PLENUMS
AIR PUMP BELTS
AIR PUMPS (ELECTRIC-DRIVEN)
AIR TUBES
ASPIRATOR, CHECK AND DECEL VALVES
BAFFLES
BALLAST PRIMARY SUPPLY RESISTOR WIRES
BALLAST RESISTORS AND PRIMARY SUPPLY RESISTOR WIRES
BAROMETRIC PRESSURE SENSORS
BATTERIES
BATTERY CABLES, WIRES AND CONNECTORS
BATTERY CONNECTORS
BATTERY TRAYS AND HOLD DOWN HARDWARE
BATTERY WIRES
BELT-DRIVEN AIR PUMPS
BELT IDLER ASSEMBLIES (ACCESSORY AND CAM BELTS)
BELT TENSIONERS (ACCESSORY AND CAM BELTS)
BOOST CONTROL MECHANISMS
CAMSHAFT POSITION SENSORS
CARBURETORS AND CHOKES
CASTING CORE PLUGS AND EXPANSION PLUGS
CHARGE AIR COOLERS "INTERCOOLERS" (CAC)
CHECK VALVES
CHOKES