Engine removal DODGE RAM 1999 Service Owner's Guide
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
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CO M PU TE R R ELE A R N P R O CED URES
1999 D odge P ic ku p R 1500
GENERAL INFORMATION
DaimlerChrysler Computer Relearn Procedures
INTRODUCTION
Vehicles equipped with engine or transmission/transaxle
computers may require a computer relearn procedure after the vehicle
battery is disconnected. Vehicle computers memorize and store vehicle
operation patterns for optimum driveability and performance. When the
vehicle battery is disconnected, this memory is lost, resulting in a
driveability problem. Depending on the vehicle and how it is equipped,
the following driveability problems may exist:
* Rough or unstable idle.
* Hesitation or stumble.
* Rich or lean running.
* Poor fuel mileage.
* Harsh or poor transmission/transaxle shift quality.
Default data is used until NEW data from each key start is
stored. As the computer restores its memory from each new key start,
driveability is restored.
Driveability problems may occur during the computer relearn
stage. To accelerate computer relearn process after battery removal
and installation, specified computer relearn procedures should be
performed. See appropriate procedures under specified manufacturer.
COMPUTER RELEARN PROCEDURES
ALL MODELS
NOTE: Read all procedures listed to determine why each procedure is
to be performed before proceeding.
Vehicle Driveability Computer Relearn Procedure
Manufacturer does not provide a specified computer relearn
procedure for obtaining proper driveability. If vehicle battery was
disconnected or Powertrain Control Module (PCM) was replaced, driving
the vehicle will enable the PCM to perform a computer relearn
procedure for obtaining proper driveability. Inform customer that
driveability may differ from what they are accustomed to until the PCM
completes the computer relearn procedure.
NOTE: If Powertrain Control Module (PCM) was replaced, 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\
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To program PCM and clear DTCs from ABS and SRS modules,
proceed to appropriate procedure listed. 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, proceed to appropriate procedure listed.
Programming PCM & Clearing DTCs From ABS & SRS Modules
Connect scan tool to Data Link Connector (DLC) below driver's\
side of instrument panel. Using scan tool, enter correct VIN and
mileage into PCM. Using scan tool manufacturer's instructions, clear
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![DODGE RAM 1999 Service Owners Guide COMPONENT LOCATIONS
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COMPONENT LOCATIONS
COMPONENT LOCATIONS \
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Component Location
ABS Control Module
Ram Pickup ....................... Left Side Of Engine Compartment
Ram Van/Wagon ...................................... Under Battery
Data Link Connector (DLC) ...... Lower Left Side Of Instrument Panel\
Output Shaft Speed Sensor (OSS) .......... Left Side Of Transmission\
Park/Neutral Position (PNP) Switch ....... Left Side Of Transmission\
Powertrain Control Module (PCM)
Dakota & Durango ............... Right Front Of Engine Compartment
Ram Pickup ............... Right Rear Corner Of Engine Compartment
Ram Van/Wagon ..................... Under Hood Next To Wiper Motor
Vehicle Speed Sensor (VSS) ........ On Transmission Or Transfer Case\
Extension Housing
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TROUBLE SHOOTING
ROAD TEST
Perform a road test to verify speed control malfunctions.
Ensure speedometer operation is smooth without flutter at all speeds.
Speedometer fluttering may cause surging in speed control system. For
speedometer diagnosis, see appropriate INSTRUMENT PANELS article. If
road test verifies a surge following speed control set and speedometer
operates smoothly, see OVERSHOOT/UNDERSHOOT FOLLOWING SPEED CONTROL
SET.
If road test verifies an inoperative system, and speedometer
operates smoothly, check for:
* Diagnostic Trouble Codes (DTCs). See SELF-DIAGNOSTIC
SYSTEM.
* Misadjusted brake switch. See BRAKE SWITCH under REMOVAL &
INSTALLATION.
* Poor electrical connections at servo.
* Leaking vacuum reservoir, check valve, hoses or connections.
See VACUUM SUPPLY under COMPONENT TESTS.
* Secure attachments of S/C servo cable.
* Smooth operation of throttle linkage.
* Defective PCM or wiring.
* Defective servo. See SPEED CONTROL SERVO under COMPONENT
TESTS.
To verify a speed control electronic malfunction, use scan
tool to check for DTCs. See SELF-DIAGNOSTIC SYSTEM. A speed control
malfunction may occur without setting a FTC. If no DTCs are stored, go
to CHECKING SPEED CONTROL OPERATION under SYSTEM TESTS.
OVERSHOOT/UNDERSHOOT FOLLOWING SPEED CONTROL SET
If operator repeatedly presses and releases set button with
their foot off accelerator (lift foot set) to begin speed control
operation, vehicle may accelerate and exceed desired set speed by 5
MPH and then decelerate to less than desired set speed before
achieving desired set speed.
Speed Control (S/C) has as adaptive strategy that compensates\
for variations in S/C cable lengths. When S/C is set with vehicle
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operator's foot off accelerator pedal, S/C compensates for excessive
S/C cable slack. If lift foot sets are continually used, speed control
overshoot/undershoot condition will develop.
To "unlearn" overshoot/undershoot condition, operator must
press and release set button while maintaining desired speed with
accelerator pedal, then turn S/C switch to OFF position after waiting
10 seconds. This procedure must be repeated 10-15 times to completely
unlearn overshoot/undershoot condition.
COMPONENT TESTS
WARNING: Vehicle is equipped with an air bag. Air bag must be
deactivated before servicing speed control components on or
around steering column. See appropriate AIR BAG RESTRAINT
SYSTEMS article.
NOTE: For component locations, See COMPONENT LOCATIONS. For
connector terminal identification, see CONNECTOR
IDENTIFICATION. For wiring diagram, see WIRING DIAGRAMS.
BRAKE SWITCH
Disconnect brake switch 6-pin connector. Using an ohmmeter,
check for continuity at brake switch. See Fig. 1. If continuity is not
as specified in BRAKE SWITCH CONTINUITY table, check brake switch
adjustment. See BRAKE SWITCH under REMOVAL & INSTALLATION. If brake
switch adjustment is okay, replace defective brake switch.
BRAKE SWITCH CONTINUITY
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Switch Plunger Check Between Continuity
Position Terminals
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Released 5 & 6 Yes
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Depressed 1 & 2 Yes
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3 & 4 Yes
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SPEED CONTROL SERVO
1) Start engine. Disconnect Speed Control (S/C) servo 4-pin
connector. Turn S/C on. Using a voltmeter, check voltage at S/C servo
connector terminal No. 3 (Dark Blue/Red wire). Battery voltage should
exist when brake pedal is not depressed. If battery voltage exists, go
to next step. If battery voltage does not exist, check circuit between
brake switch and S/C servo. See WIRING DIAGRAMS.
2) Connect a jumper wire between S/C servo pin No. 3 and S/C
servo connector terminal No. 3. Check voltage at S/C servo pins No. 1,
2 and 4. If battery voltage does not exist, replace S/C servo. If
battery voltage exists, go to next step.
3) Turn ignition off. Check for continuity between S/C servo
connector terminal No. 4 and ground. If continuity exists, test is
complete. If continuity does not exist, repair open ground circuit as
necessary.
VACUUM SUPPLY
Gasoline Engines
1) Disconnect vacuum hose at speed control servo. Install
vacuum gauge to disconnected vacuum hose. Start engine and observe
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10) Depress and release CANCEL switch. If S/C disengages, go
to next step. If S/C did not disengage, repair is not complete. Check
for related TSBs and return to TROUBLE SHOOTING, if necessary.
11) Ensure vehicle speed is greater than 35 MPH. Engage speed
control. Turn S/C on/off switch to OFF position. If speed control
disengages, system is operating correctly. Repair is complete. If
speed control does not disengage, repair is not complete. Check for
related TSBs and return to TROUBLE SHOOTING, if necessary.
TEST VER-5A
NOTE: If PCM has been replaced and correct VIN and mileage have not
been programmed, a FTC will be set in ABS and air bag
modules. If vehicle is equipped with a Sentry Key Immobilizer
Module (SKIM), sentry key data must be updated to enable
starting. See COMPUTER RELEARN PROCEDURES article in GENERAL
INFORMATION.
1) If vehicle is not equipped with a diesel engine, go to
next step. If vehicle is equipped with a diesel engine, and PCM has
been disconnected or replaced, battery has been disconnected, or
Accelerator Pedal Position Sensor (APPS) has been disconnected or
replaced, APPS calibration must be programmed into PCM (diesel only).
Turn ignition on. Slowly press accelerator pedal to floor and slowly
release. DO NOT attempt to adjust screws or disassemble APPS. Go to
next step.
2) On all engines, if vehicle is equipped with ABS or air
bag, enter correct VIN and mileage in PCM. Erase DTCs in ABS and air
bag modules. Inspect vehicle to ensure all engine and speed control
system components are connected.
3) If there are any DTCs that have not been repaired, go to
SELF-DIAGNOSTIC SYSTEM. After all DTCs have been repaired, run
appropriate monitor for previously repaired FTC.
4) Connect scan tool to DLC. Ensure fuel tank is at least 1/4
full. Turn off all accessories. Allow PCM to run appropriate monitor
and increment appropriate good trip. Enabling conditions must be met
before monitor will run.
5) Using scan tool, monitor pretest enabling conditions until
all conditions have been met. Once enabling conditions have been met,
monitor appropriate monitor.
6) If repaired FTC has reset or was seen in monitor while on
road test, repair is not complete. Check for TSBs or flash updates and
return to TROUBLE SHOOTING.
7) If appropriate monitor ran, good trip counter incremented
and no DTCs have been set, repair is complete.
REMOVAL & INSTALLATION
WARNING: Vehicle is equipped with an air bag. Air bag must be
deactivated before servicing speed control components on or
around steering column. See AIR BAG RESTRAINT SYSTEMS -
TRUCKS article.
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.
BRAKE SWITCH
Removal
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Fully depress brake pedal and rotate brake switch
counterclockwise approximately 30 degrees. Remove brake switch from
bracket. Depress lock tabs holding brake switch mounting bracket and
separate harness connector from brake switch.
Installation
1) Before installing brake switch, reset adjustable plunger
by pulling on plunger head until plunger reaches end of travel.
Connect harness connector to brake switch. Depress brake pedal and
insert brake switch into keyed hole in mounting bracket. Rotate brake
switch clockwise into locked position.
2) Gently pull back on brake pedal until pedal will go no
further. This causes the brake switch plunger to ratchet backward to
the correct position. No further adjustment is required.
SPEED CONTROL SERVO
Removal (Except Ram Van & Ram Wagon)
1) Disconnect negative battery cable. Disconnect electrical
connector and vacuum hose from servo. Using finger pressure only, push
servo cable connector from throttle body bellcrank pin. DO NOT pull
cable connector perpendicular to bellcrank.
2) Remove 2 servo cable mounting nuts. Pull servo cable
sleeve away from mounting bracket to expose cable retaining clip.
Remove retaining clip. Remove servo.
Removal (Ram Van & Ram Wagon)
1) Disconnect negative battery cable. Remove engine cover.
Remove air cleaner assembly. Using finger pressure only, push servo
cable connector from throttle body bellcrank pin. DO NOT pull cable
connector perpendicular to bellcrank.
2) Remove right headlight assembly. Disconnect vacuum hose
and electrical connector at servo. Remove 2 servo mounting bracket
bolts. Remove 2 servo cable mounting nuts. Pull servo cable sleeve
away from mounting bracket to expose cable retaining clip. Remove
retaining clip. Remove servo.
Installation (All Models)
With throttle in full open position, align hole in speed
control cable sleeve with hole in servo pin. Install retaining clip.
To complete installation, reverse removal procedure. Tighten mounting
bolts/nuts to 75 INCH lbs. (8.5 N.m).
SPEED CONTROL SWITCHES
Removal & Installation
Turn ignition off. Disconnect negative battery cable. Wait 2
minutes for air bag system to discharge reserve voltage. Remove 2
screws holding air bag assembly to steering column. Separate air bag
assembly from steering column and disconnect air bag, horn and speed
control switch connectors. Remove screws securing speed control switch
to air bag assembly. Separate speed control switch from air bag
assembly. To install, reverse removal procedure.
WIRING DIAGRAMS
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(1) - Approximate drive axle capacity listed. Lubricant level should
be within 1/2" below bottom of oil filler hole in axle housing
cover.
( 2) - Add container of Mopar Gear Oil Friction Modifier when
refilling.
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FLUID TYPE
Use SAE 80W-90 or SAE 90W hypoid gear lubricant with MIL-L-
2105-B and API GL-5 ratings. Also add a container of Mopar Gear Oil
Friction Modifier when refilling.
FLUID DRAIN & REFILL
1) With lubricant of rear axle assembly at normal operating
temperature, raise and support vehicle so rear wheels are free to
rotate. Clean around axle housing cover. Loosen axle housing cover
bolts. Drain lubricant from axle housing. Remove bolts and axle
housing cover.
2) Position differential so hole in differential case faces
down. Wipe all accessible areas of axle housing. Ensure sealing
surfaces on axle housing and cover are clean. Apply a 1/4" thick bead
of silicone sealant on inside of bolt holes and along sealing surfaces
on axle housing cover.
3) Install axle housing cover, axle identification tag and
retaining bolts. Tighten bolts to 30 ft. lbs. (41 N.m). Remove oil
filler plug. Add a container of Mopar Gear Oil Friction Modifier. Fill
axle with gear lube. Install oil filler plug. Lower vehicle.
TROUBLE SHOOTING
DIFFERENTIAL NOISE
1) Ensure differential lubricant is at normal operating
temperature. Road test vehicle. Note if differential noise exists in
turns, but not during straight-ahead driving. Probable cause is
incorrect or insufficient rear axle lubricant or additive.
2) Drain and refill rear axle. See FLUID DRAIN & REFILL under
LUBRICATION. Road test vehicle and note if noise still exists, it may
be necessary to disassemble rear axle so differential can be repaired.
See RBI FULL-FLOATING AXLES article for removal of differential case.
TESTING
NOTE: Power-Lok differential can be tested without removing
differential carrier from axle housing. Either test can be
used to check drive axle.
TEST I
1) Place blocks under both front wheels. Ensure engine is off
and transmission is in Neutral. Release parking brake. Raise one rear
wheel until it is completely clear of the floor. Remove wheel. Install
Adapter (6790) to wheel studs, and tighten securely.
2) Using torque wrench on adapter, rotate axle, and record
torque required. Repeat procedure for remaining rear wheel position.
If rotational torque for either rear wheel is less than 30 ft. lbs.
(41 N.m) or greater than 200 ft. lbs. (271 N.m), Power-Lok unit must\
be replaced or repaired.
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TESTING
NOTE: Trac-Lok differential can be tested without removing
differential case from axle housing.
1) Place blocks under both front wheels. Ensure engine is off
and transmission is in Neutral. Release parking brake. Raise one rear
wheel until it is completely clear of the floor. Remove wheel. Install
Adapter (6790) to wheel studs and tighten securely.
2) Using torque wrench on adapter, rotate axle and record
torque required. Repeat procedure for remaining rear wheel position.
If rotational torque for either rear wheel is less than 30 ft. lbs.
(40.1 N.m) or greater than 200 ft. lbs. (271 N.m), Trac-Lok unit mus\
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be replaced or repaired.
REMOVAL & INSTALLATION
Servicing procedure is same as that used for standard
differential. See RBI FULL FLOATING AXLES article for servicing
procedures.
OVERHAUL
DIFFERENTIAL CARRIER
Disassembly
1) Place appropriate side gear holding tool in soft-jaw vise.
Position differential carrier on holding tool. Remove ring gear, if
necessary. Ring gear removal is only necessary when ring gear is being
replaced.
2) Remove roll pin holding pinion mate shaft into housing.
Remove pinion gear mate shaft. A drift and hammer can be used if
necessary. See Fig. 1.
3) Install appropriate Step Plate on lower side gear. Install
appropriate threaded forcing screw into upper side gear. See Fig. 2.
4) Thread Forcing Screw into threaded adapter disc until
forcing screw is centered in threaded adapter disc. Perform STEP 1
shown in illustration. See Fig. 2.
5) Place small screwdriver in slot of threaded adapter disc
to prevent disc from rotating. Tighten forcing screw to relieve
tension from clutch pack.
6) Remove pinion gear thrust washers. Loosen forcing screw to
release pressure from clutch pack. Install appropriate turning bar in
hole on side of differential case. Perform STEP 2 shown in
illustration. See Fig. 2.
7) Using turning bar, rotate differential case until pinion
gears can be removed. Remove pinion gears. Remove turning bar, forcing
screw, step plate, and threaded adapter disc from differential case.
8) Remove upper side gear and clutch pack. See Fig. 1. Remove
differential case from axle shaft. Remove remaining side gear and
clutch pack from differential case.
CAUTION: Mark clutch pack location for reassembly reference. Note
position of clutch pack components before removing clutch
pack retainers. Clutch packs must be assembled in correct
order and installed in original location.
9) Remove clutch pack retainers from clutch pack. Keeping
clutch pack components in correct order, disassemble clutch pack.
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NOTE: Whenever transmission or drivetrain service is performed
that affects the suspension alignment, for example,
removing the engine cradle, it is required that the
alignment be checked and corrected if necessary.
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLY INSPECTION \
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Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ........... ( 2) Require repair or
replacement of the automatic
transmission/transaxle
assembly.
( 1) - It is Required that the torque converter and all other
failure related components be inspected for cause and
condition.
( 2) - For components not requiring removal of the assembly,
refer to the component listing in this document.
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DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES
NOTE: Does not include half shafts.
DIFFERENTIAL AND FINAL DRIVE ASSEMBLY INSPECTION
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Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ... Require repair or replacement
of the differential assembly.
( 1) - For components not requiring removal of the assembly,
refer to the component listing in this document.
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MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLY INSPECTION \
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Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ... Require repair or replacement
of the manual
transmission/transaxle
assembly.
( 1) - For components not requiring removal of the assembly,
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TROUBLE SHOOTING
NOTE: To trouble shoot mechanical engine components, see
appropriate table in TROUBLE SHOOTING article in GENERAL
INFORMATION.
REMOVAL & INSTALLATION
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.
NOTE: For installation reference, label all electrical connectors,
vacuum hoses and fuel lines before removal. Also place mating
marks on engine hood and other major assemblies before
removal.
FUEL PRESSURE RELEASE
CAUTION: Fuel system is under pressure. Pressure must be released
before servicing fuel system components.
Gasoline
1) Disconnect negative battery cable. Loosen fuel tank cap to
release tank pressure. Press on filler tube flap to relieve any
additional tank pressure.
NOTE: Fuel filler tube has spring-loaded flap located below fuel
fill cap to serve as secondary seal if fuel fill cap is not
tightened. It is part of EVAP monitor system when vehicle is
equipped with leak detection pump (LDP). Vehicle may be
equipped with flap installed into fuel filler tube even if
vehicle is NOT equipped with LDP and EVAP monitor system.
2) Remove fuel pump relay from Power Distribution Center
(PDC). For location of relay, refer to label on underside of PDC
cover. Start and run engine until it stalls. Attempt restarting engine
until it will no longer run.
3) Unplug connector from an injector. Attach one end of a
jumper wire (18 gauge or smaller) with alligator clips to either
injector terminal. Connect other end of jumper wire to positive side
of battery. Connect one end of a second jumper wire to remaining
injector terminal.
WARNING: Powering an injector for more than a few seconds will
permanently damage injector.
4) Touch other end of second jumper wire to negative terminal
of battery for no more than a few seconds. Place a rag below fuel
line. Disconnect quick-connect fitting at fuel rail. See FUEL LINE
DISCONNECT FITTINGS. Return fuel pump relay to PDC.
Compressed Natural Gas Fuel Tube Purging (5.2L)
1) Close control valve (clockwise) on all fuel cylinders.
Open manual shutoff valve (open when handle is parallel to fuel
tubes).
2) Start and operate engine until it runs out of fuel.
Attempt 3 more engine starts. If check valve or fuel fill receptacle
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is to be serviced, slowly loosen inlet side of fuel fill tube fitting
at check valve. It is normal for approximately 25 psi of residual
natural gas pressure to flow from loosened fitting. At this point, all
fuel tubes are purged of natural gas between fuel cylinders and
engine. It is now okay to open fuel system.
WARNING: Fuel cylinders still contain high-pressure fuel.
Compressed Natural Gas Fuel Cylinder Purging (5.2L)
1) Open manual shutoff valve. Open only fuel control valve(s)\
(counterclockwise) on fuel cylinder(s) to be serviced. Close all oth\
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control valve(s) (clockwise) on fuel cylinder(s) not being service\
d.
2) Start and operate engine until it runs out of fuel.
Attempt 3 more engine starts. At this point, all fuel tubes and opened
cylinders are purged of natural gas between fuel cylinders and engine.
It is now okay to open fuel system.
WARNING: Fuel cylinders not being serviced still contain high-pressure
fuel.
FUEL LINE DISCONNECT FITTINGS
Removal & Installation (Tab Type Fitting)
1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect negative battery cable. Ensure area around fuel line and
disconnect fitting is clean. Place shop towel around fuel line.
2) On 2-tab connectors, squeeze retainer tabs together and
pull fuel tube/quick-connect fitting assembly off of fuel tube nipple.
On single-tab connectors, use screwdriver to pry up pull tab. See
Fig. 1 . Raise pull tab until it separates from quick-connect fitting.
Discard old pull tab. Disconnect quick-connect fitting from fuel line.
CAUTION: DO NOT install a quick-connect fitting without retainer being
either in fuel tube or already in quick-connect fitting.
After installing fuel line in disconnect fitting, pull on
fuel line and disconnect fitting to ensure fuel line is
locked in place.
3) To install, coat fuel tube nipple with clean 30W engine
oil. Insert quick-connect fitting into fuel tube until stop on fuel
tube rests against back of quick-connect fitting.
4) On single-tab connectors, obtain NEW pull tab. Push tab
down until it locks into quick-connect fitting. On 2-tab connectors,
firmly pull on fuel tube and fitting to ensure retainer and quick-
connect fitting are locked.
Removal & Installation (Retainer Type Fitting)
1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect negative battery cable. Ensure area around fuel line and
disconnect fitting is clean. Place shop towel around fuel line.
2) Pull backward on disconnect fitting while depressing
plastic ring into disconnect fitting. See Fig. 2. Separate fuel line
from disconnect fitting.
NOTE: Plastic retainer ring must be pressed squarely into fitting
body. If retainer is cocked during removal, it may be
difficult to disconnect fitting. Use open-end wrench on
shoulder of plastic retainer to ease disconnection.
3) To install, ensure plastic ring is in outward position
(away from disconnect fitting). If plastic ring is in inward position
(toward disconnect fitting), disconnect fitting must be replaced.
4) Lubricate end of fuel line with 30W engine oil. Insert