engine DODGE RAM 1999 Service Repair Manual

TIE ROD ENDS (INNER AND OUTER)
TRACK BARS
TRAILING ARMS
WHEEL BEARINGS, RACES AND SEALS
Wheel Alignment
WHEEL ALIGNMENT
Wheels and Tires
TIRES
VALVE STEMS
WHEEL ATTACHMENT HARDWARE
WHEELS (RIMS)
MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
1) a Pledge of Assurance to their Customers and 2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
are continually re-published. In addition to these, standards for
Drive Train and Transmissions have recently been promulgated.
Participating shops utilize these Uniform Inspection & Communication
Standards as part of the inspection process and for communicating
their findings to their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not
satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-

profit organizations. MAP conducted pilot programs in twelve states
before announcing the program nationally in October, 1998. During the
pilots, participating repair shops demonstrated their adherence to the
Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some
"teeth" in the program, an accreditation requirement for shops was
initiated. The requirements are stringent, and a self-policing method
has been incorporated which includes the "mystery shopping" of
outlets.
We welcome you to join us as we continue our outreach... with
your support, both the automotive repair industry and your customers
will reap the benefits. Please visit MAP at our Internet site www.
motorist.org or contact us at:
1444 I Street, NW Suite 700
Washington, DC 20005
Phone (202) 712-9042 Fax (202) 216-9646
January 1999
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
It is MAP policy that all exhaust, brake, steering,
suspension, wheel alignment, drive-line, engine performance and
maintenance, and heating, ventilation and air conditioning, and
electrical services be offered and performed under the standards and
procedures specified in these sections.
Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be "Required" or
"Suggested". In addition, suggestions may be made to satisfy the
requests expressed by the customer.
When a component is suggested or required to be repaired or
replaced, the decision to repair or replace must be made in the
customer's best interest, and at his or her choice given the options
available.
This section lists the various parts and conditions that
indicate a required or suggested service or part replacement.
Although this list is extensive, it is not fully inclusive. In
addition to this list, a technician may make a suggestion. However,
any suggestions must be based on substantial and informed experience,
or the vehicle manufacturer's recommended service interval and must be
documented.
Some conditions indicate that service or part replacement is
required because the part in question is no longer providing the
function for which it is intended, does not meet a vehicle
manufacturer's design specification or is missing.
Example:
An exhaust pipe has corroded severely and has a hole in it
through which exhaust gases are leaking. Replacement of the
exhaust pipe in this case is required due to functional
failure.
Example:
A brake rotor has been worn to the point where it measures
less than the vehicle manufacturer's discard specifications.
Replacement of the rotor is required because it does not meet
design specifications.

Fig. 6: Engine Driveability & Automatic Transmission


I - S YSTE M /C O M PO NEN T T E STS

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - System & Component Testing - Trucks - Diesel
Ram Pickup
INTRODUCTION
Before testing separate components or systems, perform
procedures in BASIC DIAGNOSTIC PROCEDURES - TRUCKS - DIESEL article.
Since many computer-controlled and monitored components set a
diagnostic trouble code if they malfunction, also perform procedures
in SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS article.
NOTE: Testing individual components does not isolate short or open
circuits. Perform all voltage tests with a Digital Volt
-Ohmmeter (DVOM) with a minimum 10-megohm input impedance,
unless stated otherwise in test procedure. Use ohmmeter to
isolate shorted or open wiring harness.
AIR INDUCTION SYSTEMS
INTAKE MANIFOLD AIR HEATER SYSTEM
For testing information on intake manifold air heater system,
perform procedures in SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS
article.
INTERCOOLER
Cleaning and inspection procedures for intercooler is the
only information available from manufacturer. See INTERCOOLER under
AIR INDUCTION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - TRUCKS -
DIESEL article.
TURBOCHARGER
NOTE: Manufacturer does not recommend turbocharger disassembly.
Turbocharger overhaul should be performed only by an
authorized repair facility.
Turbocharger Boost Pressure
Turbocharger boost pressure testing information is not
available at time of publication.
TURBOCHARGER WASTEGATE
See CONTROL ROD ADJUSTMENT under TURBOCHARGER WASTEGATE in
ON-VEHICLE ADJUSTMENTS - TRUCKS - DIESEL article.
COMPUTERIZED ENGINE CONTROLS
POWERTRAIN CONTROL MODULE (PCM)
The PCM is located on firewall at passenger's side rear
corner of engine compartment. See Fig. 1. The PCM power and ground
circuits may be checked by performing specified test. See DTC P0601 in
SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS article.

Fig. 1: Locating Powertrain Control Module (PCM)
Courtesy of Chrysler Corp.
ENGINE SENSORS & SWITCHES
SENSORS
Battery Temperature Sensor
1) Battery temperature sensor is snapped into battery tray,
below driver's side battery. Disconnect wiring harness at battery
temperature sensor.
2) Using ohmmeter, check resistance between electrical
terminals on battery temperature sensor. Resistance should be 9000-11,
000 ohms at 75-80
F (25-27C). Replace battery temperature sensor if
resistance is not within specification.
3) If problem exists in battery temperature sensor or wiring
circuit, a Diagnostic Trouble Code (DTC) will be stored in Powertrain
Control Module (PCM). See SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS
article.
Crankshaft Position Sensor
If problem exists in crankshaft position sensor, a Diagnostic
Trouble Code (DTC) will be stored in Powertrain Control Module (PCM)\
.
See appropriate crankshaft position sensor test in SELF-DIAGNOSTICS -
JEEP, TRUCKS & RWD VANS article.
Fuel Heater Temperature Sensor
See FUEL DELIVERY under FUEL SYSTEM.
Intake Manifold Air Temperature Sensor
Intake manifold air temperature sensor is located on top of
intake manifold, behind intake manifold air heater. For testing, see
DTC P0113: INTAKE AIR TEMPERATURE SENSOR VOLTAGE HIGH test in SELF-
DIAGNOSTICS - JEEP, TRUCKS & RWD VANS article.
Transmission Governor Pressure Sensor (A/T Models)

Transmission Overdrive Switch (A/T Models)
See TRANSMISSION under MISCELLANEOUS CONTROLS.
RELAYS & SOLENOIDS
RELAYS
A/C Clutch Relay
A/C clutch relay may also be referred to as A/C compressor
clutch relay. A/C clutch relay is located in power distribution center
at driver's side front corner of engine compartment, near battery. If
problem exists in A/C clutch relay or wiring circuit, a Diagnostic
Trouble Code (DTC) will be stored in Powertrain Control Module (PCM)\
.
See DTC P0645 in SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS article.
Auto Shutdown (ASD) Relay
ASD relay is located in power distribution center at driver's
side front corner of engine compartment, near battery. If problem
exists in ASD relay or wiring circuit, a Diagnostic Trouble Code (DTC)\
will be stored in Powertrain Control Module (PCM). See SELF-
DIAGNOSTICS - JEEP, TRUCKS & RWD VANS article.
Fuel Heater Relay
1) Fuel heater relay is located in Power Distribution Center
(PDC) next to left battery. Refer to PDC lid for relay location.
Remove relay and note terminal identification on relay. See Fig. 3.
2) Using ohmmeter, check resistance between terminals No. 85
and 86 on relay. Resistance should be 70-80 ohms. If resistance is
within specification, go to next step. If resistance is not within
specification, replace relay.
3) Using ohmmeter, ensure continuity exists between terminals
No. 30 and 87A on relay. If continuity exists, go to next step. If no
continuity exists, replace relay.
4) Using ohmmeter, ensure no continuity exists between
terminals No. 30 and 87 on relay. If no continuity exists, go to next
step. If continuity exists, replace relay.
5) Using jumper wires, connect terminal No. 85 to negative
side of 12-volt power source and terminal No. 86 to positive side of
12-volt power source. Using ohmmeter, ensure no continuity now exists
between terminals No. 30 and 87A on relay. If no continuity exists, go
to next step. If continuity exists, replace relay.
CAUTION: DO NOT allow ohmmeter leads to contact terminals No. 85 and
86 on relay when checking resistance.
6) Using ohmmeter, ensure continuity now exists between
terminals No. 30 and 87 on relay. If continuity exists, disconnect
jumper wires from relay. If no continuity exists, replace relay.
NOTE: For additional information on checking wiring circuit for
fuel heater relay, see TEST NTC-1: NO TROUBLE CODE TEST MENU
and TEST NS-SEL: NO START TEST SELECTION in SELF-DIAGNOSTICS
- JEEP, TRUCKS & RWD VANS article.

Fig. 4: Locating Intake Manifold Air Heater Relays
Courtesy of Chrysler Corp.
Transmission Relay (A/T Models)
Transmission relay may be referred to as transmission control
relay or transmission 12-volt supply relay. Transmission relay is
located in power distribution center at driver's side front corner of
engine compartment, near battery. If problem exists in transmission
relay or wiring circuit, a Diagnostic Trouble Code (DTC) will be
stored in Powertrain Control Module (PCM). See DTC P1765: TRANSMISSION\
12-VOLT SUPPLY RELAY CONTROL CIRCUIT test in SELF-DIAGNOSTICS - JEEP,
TRUCKS & RWD VANS article.
SOLENOIDS
Transmission Overdrive Solenoid (A/T Models)
See TRANSMISSION under MISCELLANEOUS CONTROLS.

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.

Fuel Transfer Pump Output Pressure
1) Remove 2 existing filter plug fittings at top of fuel
filter housing. Install 2 spring-loaded one-way check valve fittings
at inlet and outlet port. Install Fuel Pressure Test Gauge (6828) to
inlet port fitting. Prevent engine from starting by removing fuel
injection pump relay. Relay is located in Power Distribution Center
(PDC) next to left battery. Relay location is notated on PDC lid.
2) Crank engine while observing fuel pressure test gauge.
Fuel pressure should be 5-7 psi (0.35-0.49 kg/cm

). Reinstall fuel
system relay to PDC. Start engine. Fuel pressure should be minimum of
10 psi (0.7 kg/cm

). Because fuel injection pump relay was removed, a
Diagnostic Trouble Code (DTC) may have been set. Use DRB scan tool to
erase DTC. Go to PRESSURE DROP test.
Pressure Drop
Turn engine off. Remove Fuel Pressure Test Gauge (6828) from
inlet port and attach to outlet port. Start engine and note fuel
pressure. Pressure should not be more than 5 psi (0.35 kg/cm

) less
than inlet port pressure in Fuel Transfer Pump Outlet Pressure test.
See FUEL TRANSFER PUMP OUTPUT PRESSURE test. If fuel pressure is not
to specification, replace fuel filter. Go to FUEL SUPPLY RESTRICTION
test.
NOTE: Following test requires use of DRB scan tool and Periphal
Expansion Port (PEP) module. Ensure transfer pump pressure is\
okay before performing following test.
Fuel Supply Restriction
1) Disconnect fuel supply line quick-connect fitting at left
rear side of engine compartment. After disconnecting fuel line,
plastic clip will remain attached to metal fuel line at engine. Remove
clip from metal line. Snap clip into fuel supply hose. Install Rubber
Adapter Hose (6631) into ends of disconnected fuel supply line.
2) Install transducer from PEP module to brass "T" fitting on
rubber adapter hose. Connect DRB scan tool to transducer. Start engine
and record vacuum reading with engine speed at wide open throttle.
3) If vacuum reading is less than 6 in. Hg, check for
restriction in fuel supply line or fuel tank module. Repair fuel
supply line or module for restrictions as necessary. Also check fuel
pump inlet filter at bottom of module for obstructions. Go to AIR LEAK
IN FUEL SUPPLY LINE test.
NOTE: Following test requires use of a 3-foot section of 1/4" I.D.
clear tubing and 1/8" fitting.
Air Leak In Fuel Supply Line
1) Locate 2 test port plug fittings at top of fuel filter
housing. Clean fitting area. Remove test port fitting at fuel inlet
side of housing toward rear of filter housing. Install 1/8" fitting
with 1/4" O.D. nipple in place of test port. Clamp clear tubing to
fitting nipple. Place other end of hose into clear container.
2) To put fuel transfer pump into a 25 second run mode, turn
ignition switch to CRANK position, then release back to RUN position
without starting engine. Wait for air to purge from empty hose before
checking whether air bubbles are present. If bubbles are present,
check for leaks in supply line to fuel tank. If supply line is not
leaking, remove fuel tank module. Remove filter at bottom of module.
Check for leaks between supply nipple at top of module and filter
opening at bottom of module. Replace module as necessary.
Overflow Valve
1) Clean area around overflow valve and fuel return line at
injection pump. Remove overflow valve from pump and banjo fitting.

Remove and discard gaskets. Using blow gun with regulated pressure of
about 14-16 psi (0.9-1.1 kg/cm
), apply pressure to overflow valve
inlet end (injection pump side). If internal check valve releases and
air passes through valve, go to next step. If internal check valve
does not release and air does not pass through valve, replace valve.
2) Reduce air pressure to 10 psi (0.7 kg/cm

) and recheck
valve. If valve stays closed, valve is okay. If valve does not stay
closed, replace valve and gaskets.
Fuel Injection Pump
1) Ensure fuel transfer pump output pressure is within
specification before condemning fuel injection pump. See FUEL TRANSFER
PUMP OUTPUT PRESSURE. No mechanical adjustments are needed for fuel
injection timing. All timing and fuel adjustments are made by Engine
Control Module (ECM). If a DTC has been stored indicating an ENGINE
SYNC ERROR or STATIC TIMING ERROR, remove plastic access cover,
injection pump nut and washer.
2) Locate keyway behind washer. Ensure keyway aligning fuel
injection pump shaft to injection pump gear is in correct position and
pump gear has not slipped on pump shaft. Remove timing gear cover to
access timing gears. See 5.9L (24-VALVE) 6-CYLINDER DIESEL article in
ENGINES section. Use a "T" puller and separate injection pump gear
from pump shaft. Ensure keyway is installed with arrow toward rear of
pump.
NOTE: Pump timing is calibrated to pump keyway. Ensure 3-digit
number on pump keyway matches 3-digit number on fuel
injection pump data plate on side of injection pump.
See Fig. 6.
3) Ensure timing marks on crank, camshaft and pump align.
Align gears as necessary. After repair, erase DTC.
Fig. 6: Locating Fuel System Components
Courtesy of Chrysler Corp.
FUEL CONTROL