service 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 1374 of 1691
Fig. 5: Symptom Check List - Page 4
INDIVIDUAL SYSTEM-BASED CHECK LISTS
NOTE: Have the service adviser fill out these forms with the
customer whenever possible.
Page 1387 of 1691
FUEL DELIVERY
Fuel Filter/Water Separator
1) A restricted fuel filter/water separator may cause engine
starting problems, prevent engine from accelerating, low power or
White exhaust smoke.
2) When ignition is first turned on, WATER-IN-FUEL (WIF)
warning light should come on for 2 seconds to perform bulb and wiring
circuit test and then go off. WATER-IN-FUEL (WIF) warning light is
located on instrument panel, just below tachometer.
3) If WATER-IN-FUEL (WIF) warning light stays on, water
should be drained from fuel filter/water separator. To drain water
from fuel filter/water separator, ensure engine is not running. Place
drain pan below drain tube at fuel filter/water separator.
4) Rotate handle on drain valve forward, toward front of
vehicle to DRAIN position. Drain valve is located near top of fuel
filter/water separator.
5) If no water exists and a clean flow of diesel fuel exists,
rotate handle on drain valve back to CLOSE position. Go to next step.
If water exists, allow water to drain until clean flow of diesel fuel
exists. Rotate handle on drain valve back to CLOSE position. Go to
next step.
6) Verify fuel filter/water separator has been serviced
according to proper service schedule. See SERVICE & ADJUSTMENT
SPECIFICATIONS - TRUCKS article. Ensure pre-filter was cleaned when
fuel filter/water separator was serviced. Pre-filter is located at
bottom of fuel heater on driver's side of engine. No other testing
information is available from manufacturer.
Fuel Heater
1) Malfunctioning fuel heater may cause excessive wax build-
up in fuel filter/water separator during cold ambient temperatures.
Wax build-up may cause hard starting, prevent engine from
accelerating, low power, or Blue or White smoke.
2) Disconnect electrical connector at fuel heater. Fuel
heater is located in top of fuel filter housing. Using ohmmeter, check
resistance between electrical terminals on fuel heater.
3) Resistance should be about one ohm when fuel is cold, and
about 1000 ohms when fuel is warm. Replace fuel heater if resistance
is not within specification.
NOTE: Fuel heater receives battery voltage from fuel heater relay.
Fuel heater relay is located in Power Distribution Center
(PDC), next to left battery. Refer to PDC lid for relay
location. For testing of fuel heater relay, see RELAYS under
RELAYS & SOLENOIDS. Consult wiring diagram for wiring circuit
testing. See appropriate wiring diagram in WIRING DIAGRAMS
article.
Fuel Transfer Pump Preliminary Inspection
1) Check for restricted or leaking fuel supply line to fuel
transfer pump or fuel return line located on driver's side of engine.
Repair fuel supply line or fuel return line if restricted or leaking.
2) Check for fuel leaking from weep hole on housing of fuel
transfer pump. Replace fuel transfer pump if fuel is leaking from weep
hole. Check fuel transfer pump for output pressure, pressure drop,
supply restriction, and air leaks.
NOTE: Separate pressure tests are necessary because transfer pump
operates at 2 pressure cycles, depending on whether engine is
running or cranking.
Page 1452 of 1691
H - T E STS W /O C O DES - D IE SEL
1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Trouble Shooting - No Codes - Diesel
Ram Pickup
INTRODUCTION
Before using this article, perform steps in BASIC DIAGNOSTIC
PROCEDURES - TRUCKS - DIESEL and SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD
VANS articles. Use this article to diagnose driveability problems
existing when a hard Diagnostic Trouble Code (FTC) is not present.
NOTE: Some driveability problems may have been corrected by
manufacturer with a revised Powertrain Control Module (PCM).
Check with manufacturer for latest PCM application.
Symptom checks direct the technician to malfunctioning
component(s) for further diagnosis. A symptom should lead to a
specific component, system test or adjustment.
Use TEST PROCEDURES under INTERMITTENTS to locate
driveability problems that DO NOT occur when the vehicle is being
tested. These test procedures should also be used if an intermittent
(soft) FTC was present, but no problem is found during self-diagnostic\
testing.
NOTE: For specific testing procedures, see SELF-DIAGNOSTICS -
JEEP, TRUCKS & RWD VANS article. For specifications, see ON
-VEHICLE ADJUSTMENTS - TRUCKS - DIESEL or SERVICE &
ADJUSTMENT SPECIFICATIONS - TRUCKS article.
SYMPTOMS
SYMPTOM DIAGNOSIS
Symptom checks cannot be used properly unless the problem
occurs while the vehicle is being tested. To reduce diagnostic time,
ensure steps in BASIC DIAGNOSTIC PROCEDURES - TRUCKS - DIESEL and
SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS articles were performed
before diagnosing a symptom. Symptoms available for diagnosis are as
follows:
* Black Exhaust Smoke
* White Exhaust Smoke
* Blue Exhaust Smoke
BLACK EXHAUST SMOKE
* Air filter dirty or plugged:
* Air intake system restricted:
* Exhaust system restriction is above specification:
* Poor fuel quality:
* Fuel injection pump malfunctioning:
* Fuel injector malfunctioning or leaking:
* Fuel return system restricted:
* Intake manifold restricted:
* Turbocharger problem.
WHITE EXHAUST SMOKE
Page 1454 of 1691
H - T E STS W /O C O DES - G ASO LIN E
1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Trouble Shooting - No Codes - Gasoline
Avenger, Breeze, Caravan, Cirrus, Concorde, Dakota, Durango,
Intrepid, LHS, Neon, Ram Pickup, Ram Van, Ram Wagon,
Stratus, Town & Country, Sebring Convertible, Sebring
Coupe, Voyager, 300M
INTRODUCTION
Before diagnosing symptoms or intermittent faults, perform
basic diagnostic procedures in the appropriate BASIC DIAGNOSTIC
PROCEDURES article and applicable self-diagnostic tests in the
appropriate SELF-DIAGNOSTICS article. Use this article to diagnose
driveability problems existing when a hard fault code is not present.
NOTE: Some driveability problems may have been corrected by
manufacturer with a revised Powertrain Control Module (PCM).
Check with manufacturer for latest PCM application.
Symptom checks direct the technician to malfunctioning
component(s) for further diagnosis. A symptom should lead to a
specific component, system test or adjustment.
Use intermittent test procedures to locate driveability
problems that do not occur when the vehicle is being tested. These
problems may cause a noticeable driveability problem or cause the
Malfunction Indicator Light (MIL) to illuminate on some vehicles.
These test procedures should also be used if a soft (intermittent)
trouble code is present, but no problem is found during self-
diagnostic testing.
NOTE: For specific testing procedures, see appropriate SELF
-DIAGNOSTICS article. For specifications, see appropriate ON
-VEHICLE ADJUSTMENTS and SERVICE & ADJUSTMENT SPECIFICATIONS
articles.
SYMPTOMS
SYMPTOM DIAGNOSIS
Symptom checks cannot be used properly unless the problem
occurs while the vehicle is being tested. To reduce diagnostic time,
ensure basic diagnostic procedures and self-diagnostic were performed
before diagnosing a symptom. Symptoms available for diagnosis are as
follows:
* Hard Start
* Starts But Stalls
* Hesitation Or Stumble
* Surging
* Lack Of Power
* Knocking
* Engine Misfire
* Backfire
* Rough Or Erratic Idle
* Poor Fuel Economy
HARD START
Page 1460 of 1691
NOTE: Turbocharger is not serviceable and must be replaced as a
complete assembly. Turbocharger overhaul procedures should
only be performed by an authorized facility.
Turbocharger is mounted on exhaust manifold. See Fig. 1.
Exhaust gases rotate turbine wheel along with the shaft and compressor
wheel. Rotating of compressor wheel forces an increased amount of
airflow (boost pressure) through intercooler and then into intake
manifold where the air is distributed into each cylinder. Supplying
increased airflow provides improved engine performance, lower exhaust
smoke density, altitude compensation and reduced engine noise.
Turbocharger contains a wastegate which is used for controlling boost
pressure at high speeds. Turbocharger is lubricated by pressurized
engine oil from engine oiling system. Excess engine oil is returned
through turbocharger oil return line into the cylinder block.
Fig. 2: Locating Fuel System & Various Engine Components
Courtesy of Chrysler Corp.
COMPUTERIZED ENGINE CONTROLS
Page 1472 of 1691
converter lock-up. ECM uses various input signals such as transmission
temperature, output shaft speed, central module timer, engine speed,
APPS and brake switch position to determine operation of transmission
torque converter clutch solenoid. Transmission torque converter clutch
solenoid is located on transmission valve body.
FUEL SYSTEM
FUEL DELIVERY
Fuel Injection Pump
A camshaft-driven Bosch VP44 in-line fuel injection pump is
used to supply high pressure fuel to each fuel injector in precise
metered amounts at the correct time. See Fig. 2. The pump is timed to
camshaft gear. Pump output is controlled by integral Fuel Pump Control
Module (FPCM). Because of electronic control, idle speeds and pump
timing are not adjustable. See ON-VEHICLE ADJUSTMENTS - TRUCKS -
DIESEL article. FPCM can operate engine if crankshaft position sensor
signal does not exist. Fuel injection occurs near completion of
compression stroke for each cylinder.
Fuel injection pump contains an overflow valve which allows
excess fuel to return to the fuel tank. Overflow valve is located on
side of fuel injection pump and is used to attach the fuel return line
to the fuel injection pump.
Fuel Transfer Pump
Fuel transfer pump is located on driver's side of cylinder
block, above starter. See Fig. 2. A 12 volt, 12-amp electric vane-type
pump supplies low fuel pressure from fuel tank, through fuel
heater/fuel filter/water separator to fuel injection pump. Fuel
transfer pump contains internal check valves to prevent fuel from
bleeding back into fuel tank during engine shutdown. Pump will self
prime with ignition on for 2 seconds. Pump has 2 modes, 100 percent
duty cycle (10 psi) when engine is running and 25 percent duty cycle
(7 psi) when engine is cranking.
Fuel Filter/Water Separator
Fuel filter/water separator, located on left side of engine,
protects injection pump by removing water and contaminants from fuel.
See Fig. 2 . Assembly also includes fuel heater and Water-In-Fuel (WIF)
sensor.
In-Tank Fuel Filter
A separate in-tank fuel filter is attached to bottom of fuel
tank module. In-tank fuel filter does not require service under normal
conditions.
FUEL CONTROL
Fuel Injector
Fuel injector delivers atomized fuel into the cylinder.
During fuel injection, fuel pressure from fuel injection pump
increases to fuel injector opening pressure or pop pressure of 4500
psi (316 kg/cm
). This is the pressure required to lift fuel injector
needle valve from its seat, allowing fuel to be injected into the
cylinder. Once fuel pressure decreases to less then the opening
pressure, a spring forces needle valve closed and stops fuel injection
into the cylinders. Each fuel injector is connected to injection pump
by a high pressure (as much as 17,405 psi) line.
Fuel Injection Timing
Pump output is controlled by integral Fuel Pump Control
Page 1495 of 1691
Fig. 2: Identifying Oil Pan Gasket (36RH, 46RE & 47RE)
LUBRICATION
SERVICE INTERVALS
Transmission
Check transmission fluid level when performing other
underhood services. Under normal service conditions or severe service
conditions change transmission fluid, adjust bands and replace
transmission filter at specified interval. See TRANSMISSION SERVICING
INTERVALS table. Severe service conditions are conditions such as long
periods of engine idling, trailer towing, off-highway operation, snow
removal, or operating in dusty or excessively hot conditions.
TRANSMISSION SERVICING INTERVALS
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Application Months Miles
Dakota & Durango
Normal Service ........................ 30 .............. 37,500
Severe Service ........................ ( 1) ............. 12,000
Page 1496 of 1691
Ram Pickup
Gasoline Models
Light-Duty (2)
Normal Service ..................... 30 .............. 37,500
Severe Service ..................... ( 1) ............. 12,000
Medium-Duty & Heavy-Duty
Normal Service ..................... 24 .............. 24,000
Severe Service ..................... ( 1) ............. 12,000
Diesel Models
Normal Service ....................... 24 .............. 24,000
Severe Service ....................... ( 1) ............. 12,000
Ram Van/Wagon
Normal Service ........................ ( 3) ................ ( 3)
Severe Service ........................ ( 1) ............. 12,000
( 1) - Monthly interval is not available from manufacturer.
( 2) - Light-duty applies to all 1500 models and 2500 models except
5.9L diesel or 8.0L engines. Medium-duty applies to 2500 and
3500 California models with 8.0L engine. Heavy-duty applies to
2500 and 3500 Federal models with 8.0L engine and all 3500
models with 5.9L gasoline engine.
( 3) - Normal service interval is not available from manufacturer.
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Transfer Case
Check transfer case fluid level when performing other
underhood services. Under normal service conditions or severe service
conditions change transfer case fluid at specified interval. See
TRANSFER CASE SERVICING INTERVALS table. Severe service conditions are
conditions such as long periods of engine idling, trailer towing, off-
highway operation, snow removal, or operating in dusty or excessively
hot conditions.
TRANSFER CASE SERVICING INTERVALS
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Application Months Miles
Dakota
Normal Service ....................... 30 ............... 37,500
Severe Service ....................... ( 1) .............. 36,000
Ram Pickup
Gasoline Models
Light-Duty ( 2)
Normal Service .................... 30 ............... 37,500
Severe Service .................... ( 1) .............. 36,000
Medium-Duty & Heavy-Duty
Normal Service .................... 36 ............... 36,000
Severe Service .................... ( 1) .............. 36,000
Diesel Models
Normal Service ...................... 36 ............... 36,000
Severe Service ...................... ( 1) .............. 36,000
( 1) - Monthly interval is not available from manufacturer.
( 2) - Light-duty applies to all 1500 models and 2500 models except
5.9L diesel or 8.0L engines. Medium-duty applies to 2500 and
3500 California models with 8.0L engine. Heavy-duty applies to
2500 and 3500 Federal models with 8.0L engine and all 3500
models with 5.9L gasoline engine.
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Power Take-Off (PTO) Adapter (Ram Pickup 2WD 2500 & 3500)
Check PTO adapter fluid level when performing other underhood
services. Service interval is not available from manufacturer.
Page 1506 of 1691
TR AN SM IS SIO N S ER VIC IN G - M /T
1999 D odge P ic ku p R 1500
1998-99 TRANSMISSION SERVICING
CHRY - Manual Transmission - Trucks
Dakota, Ram Pickup
APPLICATION
MANUAL TRANSMISSION APPLICATIONS (TRUCKS) \
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Model Designation
Dakota
2.5L & 3.9L .............................. AX15/AS82 & ( 1) NV1500
5.2L ...................................................... NV3500
Ram Pickup
3.9L & 5.2L ............................................... NV3500
5.2L & 5.9L (Gasoline) ......................... NV4500 & NV4500HD\
5.9L Diesel & 8.0L ..................... NV4500, NV4500HD & NV5600
( 1) - NV1500 is available on 4-cylinder 2WD models only.
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TRANSFER CASE APPLICATIONS (TRUCKS) \
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Model Designation
Dakota
3.9L ....................................................... NV231
5.2L ........................................ NV231HD Or ( 1) NV242HD
5.9L ........................................ NV231HD Or ( 1) NV242HD
Ram Pickup
1500 ..................................................... NV231HD
2500 & 3500 ..................................... NV241 Or NV241HD
( 1) - NV242HD is used on automatic transmission only.
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IDENTIFICATION
TRANSMISSION
AX-15 identification numbers are located on bottom surface of
intermediate plate. NV1500 consists of 2 aluminum housings and a
removable clutch housing. NV1500 is available on 4-cylinder 2WD
models. NV3500 consists of 2 aluminum housings and a non-removable
clutch housing. NV4500 identification tag is attached to driver's side
PTO cover. NV5600 is equipped with 2 identification tags attached to
driver's side of clutch housing.
TRANSFER CASE
Transfer case identification tag is located on rear of
transfer case housing.
LUBRICATION
SERVICE INTERVALS
Page 1507 of 1691
Transmission (Dakota)
Check transmission fluid level when performing other
underhood services. Under normal service conditions, change
transmission fluid at 30 months or 37,500 miles. Under severe service
conditions, change transmission fluid at 18,000 miles. Severe service
are conditions such as long periods of engine idling, trailer towing,
off-highway operation, snow removal, or operating in dusty or
excessively hot conditions.
Transmission (Ram Pickup)
Check transmission fluid level when performing other
underhood services. Fluid change service interval information is not
available from manufacturer.
Transfer Case
Check transfer case fluid level when performing other
underhood services. On Dakota and Light-Duty Pickup, change transfer
case fluid at 37,500 miles or 30 months. On Medium-Duty and Heavy-Duty
Pickup, change transfer case fluid at 36,000 miles or 36 months.
CHECKING FLUID LEVEL
Transmission (Dakota)
1) Park vehicle on level surface. Remove transmission fill
plug from side of transmission. On AX-15 transmission, transmission
fill plug is located on driver's side of transmission. On NV3500
transmission, transmission fill plug is located near front of
transmission on passenger's side of transmission.
2) On all transmissions, fluid level should even with bottom
of fill plug hole on side of transmission. Add appropriate type of
transmission fluid if necessary. See RECOMMENDED FLUID. Install and
tighten transaxle fill plug to specification. See TORQUE
SPECIFICATIONS.
Transmission (Ram Pickup)
1) Park vehicle on level surface. Remove transmission fill
plug from side of transmission. On NV3500 transmissions, transmission
fill plug is located near front of transmission on passenger's side of
transmission. On NV4500 transmissions, transmission fill plug is
located near rear of transmission on passenger's side of transmission.
2) On all transmissions, fluid level should even with bottom
of fill plug hole on side of transmission. Add appropriate type of
transmission fluid if necessary. See RECOMMENDED FLUID. Install and
tighten transaxle fill plug to specification. See TORQUE
SPECIFICATIONS.
Transfer Case
Park vehicle on level surface. Remove transfer case fill plug
from rear of transfer case. Fluid level should even with bottom of
transfer case fill plug hole on rear of transfer case. Add appropriate
type of transfer case fluid if necessary. See RECOMMENDED FLUID.
Install and tighten transfer case fill plug to specification. See
TORQUE SPECIFICATIONS.
RECOMMENDED FLUID
Transmission (Dakota)
On AX-15 transmissions, use API 75W-90 GL-3 gear oil. On
NV1500 and NV3500 transmissions, use ONLY Mopar M/T Lube Part No.
4761526.
Transmission (Ram Pickup)