can bus 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 688 of 1691
CRANKSHAFT & MAIN BEARINGS
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
REMOVAL
Ensure all main bearing caps are marked for location on
cylinder block. Some main bearing caps have an arrow stamped on it
which must face front of engine. Remove main bearing cap bolts. Remove
main bearing caps. Carefully remove crankshaft. Use care not to bind
crankshaft in cylinder block during removal.
CLEANING & INSPECTION
Thoroughly clean crankshaft using solvent. Dry with
compressed air. Ensure all oil passages are clear and free of sludge,
rust, dirt, and metal chips.
Inspect crankshaft for scoring and nicks. Inspect crankshaft
for cracks using Magnaflux procedure. Inspect rear seal area for
grooving or damage. Inspect bolt hole threads for damage. If pilot
bearing or bushing is used, check pilot bearing or bushing fit in
crankshaft. Inspect crankshaft gear for damaged or cracked teeth.
Replace gear if damaged. Check that oil passage plugs are tight (if
equipped).
Using micrometer, measure all journals in 4 areas to
determine journal taper, out-of-round and undersize. See Fig. 20.
Some crankshafts can be reground to the next largest undersize,
depending on the amount of wear or damage. Crankshafts with rolled
fillet cannot be reground and must be replaced.
Fig. 20: Measuring Crankshaft Journal - Typical
This Graphic For General Information Only
Crankshaft journal runout should be checked. Install
crankshaft in "V" blocks or bench center. Position dial indicator
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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.
NOTE: Testing of instrument panel and gauges requires using a scan
tool to check circuits connected to Body Control Module
(BCM). See appropriate BODY CONTROL COMPUTER TESTS article.
PRELIMINARY DIAGNOSIS
NOTE: There are 2 instrument cluster connectors. These connectors
look identical. Identify connectors by wire color. See WIRING
DIAGRAMS.
Ram Pickup
1) If CCD bus controlled indicator lights and gauges do not
operate, go to step 4). If indicator lights operate and all gauges do
not operate, go to next step.
2) Check for battery voltage between ground and both sides of
fuse No. 14 in junction block. If battery voltage exists on both
sides, go to next step. If battery voltage exists on one side only,
repair short circuit and replace fuse. If battery voltage does not
exist on both sides, locate and repair open circuit. See WIRING
DIAGRAMS.
3) Disconnect negative battery cable. Remove instrument
cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Connect
negative battery cable. Measure voltage between ground and terminal
No. 6 (Yellow wire) of instrument cluster connector C1. See Fig. 1. If
battery voltage is present, reinstall instrument cluster and go to
SELF-DIAGNOSTICS. If battery voltage is not present, repair open
circuit between fuse No. 14 in junction block and instrument cluster
connector C1.
4) Turn ignition on. Measure voltage between ground and both
sides of fuse No. 17 (10-amp) in junction block. If battery voltage
exists on both sides, go to next step. If battery voltage exists on
one side only, repair short circuit and replace fuse. If battery
voltage does not exist on both sides, repair open Dark Blue wire
between ignition switch and junction block.
5) Turn ignition off. Disconnect negative battery cable.
Reconnect instrument cluster. See INSTRUMENT CLUSTER under REMOVAL &
INSTALLATION. Connect negative battery cable. Turn ignition on. Set
parking brake and observe instrument cluster brake warning light. If
brake warning light is off, go to step 7). If brake warning light is
on, go to next step.
6) Turn ignition off. Turn parking lights on and adjust
instrument panel lights dimmer rheostat to full bright position. If
instrument panel lights are on, go to step 8). If instrument panel
lights are off, repair open ground circuit to instrument cluster
connector C1 terminal No. 4 (Black/Light Green wire) or No. 5
(Black/Orange wire). See WIRING DIAGRAMS.
7) Turn ignition off and disconnect negative battery cable.
Remove instrument cluster. See INSTRUMENT CLUSTER under REMOVAL &
INSTALLATION. Connect negative battery cable. Turn ignition on.
Measure voltage between ground and instrument cluster connector C1
terminal No. 2 (Dark Blue/White wire). If battery voltage exists, go
to SELF-DIAGNOSTICS. If battery voltage does not exist, repair open
Dark Blue/White wire.
8) Turn ignition off. Disconnect negative battery cable.
Remove instrument cluster. See INSTRUMENT CLUSTER under REMOVAL &
INSTALLATION. Using an ohmmeter, check continuity between ground and
instrument cluster connector C1 terminals No. 4 (Black/Light Green
wire) and No. 5 (Black/Orange wire). If continuity exists, go to SELF\
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![DODGE RAM 1999 Service Owners Manual Use Scan Tool To Verify VSS
Signal Is Sent By PCM
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Signal Is Sent By PCM
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Use Scan Tool To Verify VSS
Signal Is Sent By PCM
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921 Not Receiving Distance Pulse Check PCM Software Level;
Message From PCM Use Scan Tool To Verify
Distance Pulse Message Is
Sent By PCM
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940 Not Receiving Air Bag Light On Check CCD Bus Connections At
Message From Air Bag Module ACM; Check ACM Fuse
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950 Not Receiving ABS Light On Message Check CCD Bus Connections
From Anti-lock Brake Control ModuleAt Anti-Lock Control Module;
Check Anti-Lock Control
Module Fuse
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999 Undefined Error Record Failure Message;
Press RESET Button To
Continue Self-Diagnostic
Test
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2) If no DTCs appear, cluster will start a walking segment
test. First, all segments will be illuminated, then each segment in
sequence. If any segment does not illuminate, repeat test to confirm
and replace instrument cluster. When walking segment test is complete,
bulb check will start.
3) If any bulb does not light, remove instrument cluster and
check bulb and bulb holder. See INSTRUMENT CLUSTER under REMOVAL &
INSTALLATION. Ensure bulb holder is properly installed in cluster. If
bulb and bulb holder are okay, replace instrument cluster. If LED does
not light, replace instrument cluster. When bulb check is complete,
gauge actuator test will start.
4) Each gauge needle should stop at 3 calibration points,
then return to relaxed position. If any gauge does not perform as
specified, remove instrument cluster. See INSTRUMENT CLUSTER under
REMOVAL & INSTALLATION. Inspect all connections between printed
circuit board and gauge terminals, repair as necessary. If connections
are okay, replace instrument cluster. Instrument cluster will
automatically exit self-diagnostics when test is complete.
SYSTEM TESTS
NOTE: There are 2 instrument cluster connectors. These connectors
look identical. Identify connector by wire color. See WIRING
DIAGRAMS.
BRAKE WARNING LIGHT INOPERATIVE
1) Ensure parking brake is released. Turn ignition on. If
brake warning light stays on, check and repair hydraulic brake system
as necessary. See appropriate DISC & DRUM article in BRAKES section.
2) If brake warning light does not illuminate when ignition
is on, check fuse No. 17 (10-amp) on Ram Pickup or fuse No. 11 (10-
amp) on Ram Van and Ram Wagon in junction block. Junction block is
located at left end cover of instrument panel. If fuse is okay, go to
next step. If fuse is blown, locate and repair cause of blown fuse.
Install new fuse and recheck system operation.
3) Turn ignition on. Measure voltage between ground and power
side of fuse No. 17 on Ram Pickup or fuse No. 11 on Ram Van and Ram
Wagon. If battery voltage is present, go to next step. If battery
voltage is not present, locate and repair open circuit between to
Page 893 of 1691
CAUTION: Disconnect negative battery cable before servicing any air
bag system, steering column or passenger side dash
component. After any repair, turn ignition key to the ON
position from passenger's side of vehicle in case of
accidental air bag inflation
AIR CONDITIONING SERVICING
WARNING: Avoid breathing R-134a refrigerant and PAG lubricant vapors,
exposure may irritate eyes, nose and throat. To remove
R-134a from system use R-134a recycling equipment that meets
SAE J2210 specifications. If accidental system discharge
occurs, ventilate work area before resuming service.
WARNING: R-134a service equipment or vehicle A/C systems SHOULD NOT
be pressure tested or leak tested with compressed air. Some
mixtures of air/R134a have shown to be combustible at
elevated pressures. These mixtures are dangerous and may
cause fire and/or explosions. See AIR CONDITIONING SERVICE
article in GENERAL INFORMATION section.
AIR CONDITIONING MAINTENANCE
WARNING: NEVER add A/C refrigerant to correct a non-cooling problem
unless pressure gauges are connected to the system by a
certified technician. Lack of cooling may be caused by a
restriction, therefore adding refrigerant can cause a
dangerous pressure rise.
ANTI-LOCK BRAKE SYSTEM
CAUTION: The anti-lock brake system contains electronic equipment that
can be susceptible to interference caused by improperly
installed or high output radio transmitting equipment. Since
this interference could cause the possible loss of the
antilock braking capability, such equipment should be
installed by qualified professionals.
On models equipped with anti-lock brake systems, ALWAYS
observe the following cautions:
* DO NOT attempt to bleed hydraulic system without first
referring to the appropriate ANTI-LOCK BRAKE SYSTEM article
in the BRAKES Section.
* DO NOT mix tire sizes. As long as tires remain close to the
original diameter, increasing the width is acceptable.
Rolling diameter must be identical for all 4 tires. Some
manufacturers recommend tires of the same brand, style and
type. Failure to follow this precaution may cause inaccurate
wheel speed readings.
* Use ONLY recommended brake fluids. DO NOT use silicone brake
fluids in an ABS-equipped vehicle.
AUTOMATIC TRANSAXLE FLUID SERVICE
WARNING: Make certain no fluid is spilled when the transaxle fluid
is inspected. Wipe up any spilled fluid completely.
AXLE FLUID
CAUTION: Axle lubricant should be changed whenever the axle has
Page 1271 of 1691
of part with damaged threads if
available; otherwise, replace
bushing.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads if
available; otherwise, replace
bushing.
Binding ................. A .. Require repair or replacement.
Deteriorated, affecting
performance ............ A .. Require repair or replacement.
Distorted, affecting
performance ............ A .. Require repair or replacement.
Leaking (fluid-filled
type) .................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .......... (1) Further inspection
required.
Rubber separating from
internal metal sleeve on
bonded bushing ......... A ............ Require replacement.
Seized .................. A ............ Require replacement.
Shifted (out of
position) .............. B .. Require repair or replacement.
Split ................... A ............ Require replacement.
Surface cracking (weather-
checked) ............... .. ........ No service suggested or
required.
( 1) - If noise isolated to bushing, suggest repair or
replacement.
CAUTION: Use only approved lubricant on rubber bushings.
Petroleum-based lubricants may damage rubber bushings.
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CENTER LINKS
CENTER LINK INSPECTION \
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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace center link.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace center link.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace center link.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace center link.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
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of part with damaged threads if
available; otherwise, replace
bushing.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads if
available; otherwise, replace
bushing.
Binding ................. A .. Require repair or replacement.
Deteriorated, affecting
performance ............ A .. Require repair or replacement.
Distorted, affecting
performance ............ A .. Require repair or replacement.
Leaking (fluid-filled
type) .................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .......... (1) Further inspection
required.
Rubber separating from
internal metal sleeve on
bonded bushing ......... A ............ Require replacement.
Seized .................. A ............ Require replacement.
Shifted (out of
position) .............. B .. Require repair or replacement.
Split ................... A ............ Require replacement.
Surface cracking (weather-
checked) ............... .. ........ No service suggested or
required.
( 1) - If noise isolated to bushing, suggest repair or
replacement.
CAUTION: Use only approved lubricant on rubber bushings.
Petroleum-based lubricants may damage rubber bushings.
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CENTER LINKS
CENTER LINK INSPECTION \
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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace center link.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace center link.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace center link.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace center link.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
Page 1462 of 1691
* Charging System
* Cruise Control System
* Intake Manifold Air Heater
* Tachometer
* Torque Convertor Clutch Engagement (A/T Only)
* Transmission Overdrive Solenoid (A/T Only) Components are
grouped into 2 categories. The first category covers INPUT
DEVICES, which control or produce voltage signals monitored
by the PCM. The second category covers OUTPUT SIGNALS, which
are components controlled by the PCM. See PCM INPUT SIGNALS
and ECM/PCM OUTPUT SIGNALS.
ECM INPUT SIGNALS
Accelerator Pedal Position Sensor (APPS)
APPS sensor is mounted on top left of engine. See Fig. 2.
Sensor provides DC voltage input signal to Engine Control Module (ECM)\
to indicate throttle position. On previous engines, there were
linkages between accelerator pedal, throttle position sensor and
injection pump. On this engine, no linkage exists between accelerator
pedal and injection pump. ECM uses input signals from APPS sensor to
determine proper fuel delivery. ECM also outputs this signal to PCM.
Battery Voltage
Battery voltage input signal provides operating voltage to
Engine Control Module (ECM). This input signal keeps ECM memory alive
and informs ECM what generator output voltage is when engine is
running. ECM memory is used to store Diagnostic Trouble Codes (DTCs),
store APPS sensor voltages from previous key cycles and provide a
speed control adaptive memory.
Camshaft Position Sensor (CMP)
Camshaft Position (CMP) sensor is a hall effect sensor (0-5
volts switched), located below injection pump in rear face of timing
gear cover. Sensor is not used for fuel control. Sensor is used only
for diagnostic purposes.
CCD Bus Circuits
These circuits are connected between Engine Control Module
(ECM) and Powertrain Control Module (PCM) to allow communication
between modules.
Crankshaft Position Sensor (CKP)
Crankshaft Position (CKP) sensor delivers input signal (35
tooth wheel with gap) to Engine Control Module (ECM) to indicate
engine speed and crankshaft position. ECM uses CKP signal along with
other input signals for controlling injector firing sequence and
timing. Sensor is located below fuel transfer pump, on side of engine
block. See Fig. 2.
Data Link Connector (DLC)
Data Link Connector (DLC) provides an input signal to Engine
Control Module (ECM) when using scan tool to retrieve Diagnostic
Trouble Codes (DTCs) from ECM. Input signal may also be used when
performing various tests on the ECM and electronic control system.
Data link connector is a 16-pin connector located at lower edge of
driver's side of instrument panel, just above accelerator pedal.
Engine Coolant Temperature (ECT) Sensor
Engine coolant temperature sensor delivers input signal to
Engine Control Module (ECM) to indicate engine coolant temperature.
ECM uses input signal for controlling fuel control and timing. Engine
coolant temperature sensor is located on front of head, near
Page 1467 of 1691
brakelines are attached to and is mounted in the engine compartment.
ECM OUTPUT SIGNALS
APPS & CKP Output To PCM
See ACCELERATOR PEDAL POSITION SENSOR (APPS) OUTPUT FROM ECM
under PCM INPUT SIGNALS.
CCD Bus
These circuits are connected between Engine Control Module
(ECM) and Powertrain Control Module (PCM) to allow communication
between modules.
DLC Output
Data Link Connector (DLC) is connected to Engine Control
Module (ECM). Using a scan tool, data can be retrieved (output) from\
ECM.
5-Volt Sensor Supply Output
Engine Control Module (ECM) supplies a 5-volt reference
signal to the following sensors:
* Crankshaft Position (CKP) Sensor
* Camshaft Position (CMP) Sensor
* Intake Air Temperature (IAT) Sensor
* Engine Oil Pressure Sensor
* Manifold Absolute Pressure (MAP) Sensor
Engine Control Module (ECM) also supplies voltage to the
following sensors:
* Accelerator Pedal Position Sensor (APPS)
* Intake Air Temperature (IAT) Sensor
* Engine Oil Pressure Sensor
* Engine Coolant Temperature (ECT) Sensor
* Manifold Absolute Pressure (MAP) Sensor
* Water-In-Fuel (WIF) Sensor
Fuel Injection Pump Relay
The Engine Control Module (ECM) energizes the fuel injection
pump and integral Fuel Pump Control Module (FPCM) through the relay.
When ignition is turned on, ECM supplies 12 volts to fuel injection
pump relay, located in Power Distribution Center.
Fuel Pump Control Module (FPCM)
Fuel Pump Control Module (FPCM) controls fuel pump using
inputs from Engine Control Module (ECM). FPCM is integral to top of
fuel pump. ECM and FPCM are interconnected together for fuel injection
control.
Fuel Transfer Pump
Engine Control Module (ECM) supplies power to fuel transfer
pump. Transfer fuel pump supplies fuel under low pressure (14 psi)
while engine is running to fuel injection pump. Fuel transfer pump
supplies an excess of fuel to cool fuel injection pump. Excess fuel is
returned to fuel tank by fuel injection pump.
Intake Manifold Air Heater Relays
Intake manifold air heater relays provide voltage to intake
manifold air heater for warming of intake. See Fig. 5. Warming of
intake air aids in engine starting and improved driveability during
cold ambient temperatures. Intake manifold air heater relays are
mounted on inner wheelwell, below driver's side battery. See Fig. 6.
Page 1470 of 1691
WAIT-TO-START Warning Light
WAIT-TO-START warning light is located on instrument panel,
just below the speedometer. WAIT-TO-START warning light will come on
for a short period and then go off as a bulb and wiring circuit test
each time ignition switch is turned to the ON position. If Engine
Control Module (ECM) determines intake manifold air temperature is
less than 59
F (15 C) by input signal received from intake manifold
air temperature sensor, ECM delivers output signal to operate WAIT-TO-
START warning light and intake manifold air heater for a preheat
cycle.
WAIT-TO-START warning light will remain on until intake
manifold air heater preheat cycle is complete. WAIT-TO-START warning
light will flash on and off if intake manifold air temperature sensor
signal to ECM is not within a specified value and Diagnostic Trouble
Code (FTC) will be stored in ECM memory.
WATER-IN-FUEL Warning Light
WATER-IN-FUEL warning light is located on instrument panel,
just below tachometer. WATER-IN-FUEL warning light will come on for a
short period and then go off as a bulb and wiring circuit test each
time ignition switch is turned to the ON position. If Engine Control
Module (ECM) determines water exists in fuel/water separator by input
signal from Water-In-Fuel (WIF) sensor, ECM will deliver output signal\
to turn on the WATER-IN-FUEL warning light.
ECM/PCM OUTPUT SIGNALS
A/C Clutch Relay
The Engine Control Module (ECM) controls A/C compressor
operation by controlling ground circuit for A/C clutch relay. ECM de-
energizes A/C clutch relay if engine coolant temperature is more than
257
F (125 C). The A/C clutch relay is located in power distribution
center at driver's side front corner of engine compartment, near the
battery.
Automatic Shutdown (ASD) Relay
The Engine Control Module (ECM) controls ASD operation by
controlling ground circuit for ASD relay. ASD provides voltage to
operate generator field control for charging system. ASD relay is
located in power distribution center at driver's side front corner of
engine compartment, near the battery. Automatic Shutdown (ASD) relay
may also be referred to as Auto Shutdown (ASD) relay.
CCD Bus
These circuits are connected between Engine Control Module
(ECM) and Powertrain Control Module (PCM) to allow communication
between modules.
Cruise Control System
Engine Control Module (ECM) regulates cruise control system
operation by controlling vacuum at cruise control servo. Vacuum is
controlled by use of vacuum and vent solenoids in cruise control
servo.
Data Link Connector
Engine Control Module (ECM) provides output information at
Data Link Connector (DLC) when using scan tool to perform various
tests on the ECM and electronic control system. Data link connector is
a 16-pin connector located at lower edge of driver's side of
instrument panel, just above the accelerator pedal.
5-Volt Sensor Supply Output
Powertrain Control Module (PCM) supplies a 5-volt reference
Page 1526 of 1691
VEH IC LE C O M MUNIC ATIO N
1999 D odge P ic ku p R 1500
1999 ACCESSORIES & EQUIPMENT
CHRY - Vehicle Communications
Ram Pickup
IDENTIFYING VEHICLE COMMUNICATION PROBLEMS
Connect scan tool to Data Link Connector (DLC) to retrieve
messages. If scan tool message is blank, disconnect scan tool. Ensure
ground circuit has continuity at DLC terminal No. 4. Ensure 12 volts
exists at DLC terminal No. 16. Check power to DLC terminal No. 16 from
Power Distribution Center (PDC) fuse No. 12. Try another scan tool
and/or cable. If scan tool DTC or fault message is present, see
following bus fault messages list and proceed to appropriate DTC or
fault message:
* BUS (+) & BUS (-) OPEN
* BUS (+) OPEN
* BUS (-) OPEN
* BUS (+) & BUS (-) SHORTED TOGETHER
* BUS BIAS LEVEL TOO HIGH
* BUS BIAS LEVEL TOO LOW
* NO BUS BIAS
* NO RESPONSE AIR BAG CONTROL MODULE
* NO RESPONSE CENTRAL TIMER MODULE
* NO RESPONSE INSTRUMENT CLUSTER
* NO RESPONSE POWERTRAIN CONTROL MODULE
* NO RESPONSE COMPASS/MINI-TRIP SYSTEM
* NO RESPONSE RADIO
* NO TERMINATION
* NOT RECEIVING BUS MESSAGES CORRECTLY
* BUS SHORT TO 5 VOLTS
* BUS SHORT TO BATTERY
* BUS SHORT TO GROUND
BUS (+) & BUS (-) OPEN, (BUS (+) OPEN OR BUS (-) OPEN)
NOTE: For connector terminal identification and wiring diagrams,
see BODY CONTROL COMPUTER - INTRODUCTION article. Perform
VERIFICATION TEST VER-1 after each repair.
CAUTION: Always turn ignition off prior to disconnecting any module
connector.
1) Disconnect scan tool. Ensure ignition is on. Using an
external voltmeter, measure voltage between ground and DLC terminal
No. 3 (Violet/Brown wire). If voltage is not 1.8-2.3 volts, go to step\
3). If voltage is 1.8-2.3 volts, go to next step.
2) Measure voltage between ground and DLC terminal No. 11
(White/Black wire). If voltage is not 1.8-2.3 volts, go to next step.
If voltage is 1.8-2.3 volts, replace scan tool cable or scan tool.
3) Connect jumper wire between ground and DLC connector
terminal No. 11 (White/Black wire). Turn ignition off. Remove
instrument cluster. Using external ohmmeter, measure resistance
between ground and instrument cluster connector C1 terminal No. 9
(White/Black wire). If resistance is less than 5 ohms, go to next
step. If resistance is 5 ohms or more, repair open White/Black wire.
4) Disconnect jumper wire. Connect jumper wire between ground
and DLC connector terminal No. 3 (White/Black wire). Measure