belt DODGE RAM 1999 Service Workshop Manual

service intervals.
Missing ................. C ........ (3) Require replacement.
Noisy ................... 2 .......... ( 4) Further inspection
required.
See note below.
Plies separated ......... A ............ Require replacement.
Tension out of
specification .......... B ........... Require adjustment or
replacement.
Teeth missing ........... A ............ Require replacement.
( 1) - Inspect belt tensioners, pulleys, and cover.
( 2) - Determine cause of incorrect alignment and require repair.
( 3) - CAUTION: Internal engine damage may result from timing
belt damage/failure.
( 4) - Determine cause of noise and suggest repair.









\









\









\









\









\









\









\


TORQUE STRUTS
TORQUE STRUT INSPECTION








\









\









\









\









\









\









\


Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Binding ................. A ............ Require replacement.
Body dented ............. A .......... ( 1) Further inspection
required.
Body punctured .......... A ............ Require replacement.
Bushing deteriorated,
affecting performance .. A ............ Require replacement.
Bushing deteriorated, not
affecting performance .. .. ........ No service suggested or
required.
Bushings missing ........ C ............ Require replacement.
Bushings separated from
mounting eye ........... 1 ............ Suggest replacement.
Damping (none) .......... A ............ Require replacement.
Leaking oil, enough for
fluid to be running down
the body ............... A ............ Require replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .......... ( 2) Further inspection
required.
Piston rod bent ......... A ............ Require replacement.
Piston rod broken ....... A ............ Require replacement.
Seized .................. A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Require replacement of units where dents restrict strut
piston rod movement. If dents don't restrict movement, no
service is suggested or required.
( 2) - If noise is isolated to shock or strut, suggest replacement.

GEN ER AL C O OLIN G S YSTE M S ER VIC IN G
1999 D odge P ic ku p R 1500
GENERAL INFORMATION
General Cooling System Servicing
* PLEASE READ THIS FIRST *
The following article is for general information only.
Information may not apply to all years, makes and models. See specific
article in the ENGINE COOLING section.
DESCRIPTION
The basic liquid cooling system consists of a radiator, water
pump, thermostat, electric or belt-driven cooling fan, pressure cap,
heater, and various connecting hoses and cooling passages in the block
and cylinder head.
MAINTENANCE
DRAINING
Remove radiator cap and open heater control valve to maximum
heat position. Open drain cocks or remove plugs in bottom of radiator
and engine block. In-line engines usually have one plug or drain cock,
while "V" type engines will have 2, one in each bank of cylinders.
CLEANING
A good cleaning compound removes most rust and scale. Follow
manufacturer's instructions in the use of cleaner. If considerable
rust and scale has to be removed, cooling system should be flushed.
Clean radiator air passages with compressed air.
FLUSHING
CAUTION: Some manufacturers use an aluminum and plastic radiator.
Flushing solution must be compatible with aluminum.
Back Flushing
Back flushing is an effective means of removing cooling
system rust and scale. The radiator, engine and heater core should be
flushed separately.
Radiator
To flush radiator, connect flushing gun to water outlet of
radiator and disconnect water inlet hose. To prevent flooding engine,
use a hose connected to radiator inlet. Use air in short bursts to
prevent damage to radiator. Continue flushing until water runs clear.
Engine
To flush engine, remove thermostat and replace housing.
Connect flushing gun to water outlet of engine. Flush using short air
bursts until water runs clean.
Heater Core
Flush heater core as described for radiator. Ensure heater
control valve is set to maximum heat position before flushing heater.

pointer is at one o'clock position. Push in on knob slightly and
continue rotating knob to its full clockwise stop. Place knob pointer
at a position about .32" (8 mm) beyond end of Red stripe. Release
knob. If knob is pointing at about .32" (8 mm) beyond end of Red
stripe, go to next step. If knob is not pointing at about .32" (8 mm)
beyond end of Red stripe, go back to step 2) and repeat adjustment
procedure.
4) Rotate temperature control knob counterclockwise so that
knob pointer is at 12 o'clock position. Push temperature control knob
straight into heater control panel until perimeter of knob (not knob
pointer) is flush with base of heater control panel.
5) Rotate temperature control knob to its full clockwise
stop. Release knob. Knob pointer should be aimed at end of Red stripe.
If knob is pointed at end of Red stripe, go to next step. If knob is
not pointed at end of Red stripe, go back to step 2) and repeat
adjustment procedure.
6) Rotate temperature control knob to its full
counterclockwise stop. Release knob. If knob springs back, self-
adjuster clip securing temperature control cable to blend-air door
lever is improperly installed. See TEMPERATURE CONTROL CABLE R & I
under REMOVAL & INSTALLATION. If knob does not springs back,
temperature control cable adjustment is complete.
TROUBLE SHOOTING
HEATER PERFORMANCE
Check cooling system. Check serpentine drive belt tension.
Check radiator and radiator fan operation. Ensure that accessory
vacuum supply line is connected at power brake booster (Dakota) or
engine vacuum source (except Dakota).
TESTING
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all SERVICE PRECAUTIONS and DISABLING &
ACTIVATING AIR BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY
article.
BLOWER MOTOR RELAYS
1) Blower motor relay is located in Power Distribution Center
(PDC). On Ram Van/Wagon, high speed blower motor relay is located in
engine compartment (on side of heater assembly). On all models,
disconnect negative battery cable. Remove blower motor relay. Using an
ohmmeter, check for continuity between terminals No. 87A and 30 of
relay. See Fig. 1. If continuity does not exist, replace relay. If
continuity exists, go to next step.
2) Using an ohmmeter, check for continuity between terminals
No. 30 and 87 of relay. If continuity exists, replace relay. If
continuity does not exist, go to next step.
3) Measure resistance between terminals No. 85 and 86 of
relay. Reading should be 70-80 ohms. If reading is not as specified,
replace relay. If reading is as specified, go to next step.
4) Using jumper wires, connect battery voltage to terminal
No. 86 and ground terminal No. 85. See Fig. 1. Check that continuity
exists between terminals No. 30 and 87. Check that continuity does not
exist between terminals No. 87A and 30. If continuity is not as
specified, replace blower motor relay. If continuity is as specified,
relay is okay.

Parking Brake Switch ...................... Analog Instrument Panels
Park Lights ........................................ Exterior Lights
Park/Neutral Position Switch .............................. Starters
Engine Performance
Anti-Theft System
Body Control Module
Perimeter Lighting Control Relay ................... Exterior Lights
Power Amplifier ..................................... Power Antennas
Power Antenna Module ................................ Power Antennas
Power Antenna Motor ................................. Power Antennas
Power Distribution Center ....................... Power Distribution
Generators & Regulators
Starters
Power Door Lock Motors ............................ Power Door Locks
Power Mirror Motors .................................. Power Mirrors
Memory Systems
Power Sliding Door Controller .............. Power Sliding Side Door
Power Seat Motors ...................................... Power Seats
Memory Systems
Power Steering Pressure Switch .................. Engine Performance
Power Top Motor .............................. Power Convertible Top
Power Top Relay(s) ........................... Power Convertible Top\
Powertrain Control Module ....................... Engine Performance
Analog Instrument Panels
Cruise Control Systems
Data Link Connectors
Generators & Regulators
Starters
Power Window Motors .................................. Power Windows
Power Window Relay(s) ................................ Power Windows\
Radiator Fan Motor(s) ........................ Electric Cooling Fans\
Radiator Fan Relay(s) ........................... Engine Performance\
Electric Cooling Fans
Rainsense Module .............................. Wiper/Washer Systems
Raise Relay .................................. Power Convertible Top
Remote Anti-Theft Personality (RAP) Module ....... Anti-Theft System\
Starters
Warning Systems
Seat Belt Pretensioners ................... Air Bag Restraint System
Seat Belt Retractor Solenoid .................... Passive Restraints
Seat Belt Switch .......................... Air Bag Restraint System
Passive Restraints
Shift Interlock Solenoid ................... Shift Interlock Systems
Shift Lock Actuator ........................ Shift Interlock Systems
Side Marker Lights ................................. Exterior Lights
SIR Coil Assembly (Clockspring) ........... Air Bag Restraint System\
Slip Ring (Clockspring) ................... Air Bag Restraint System\
Steering Column Switches
SRS Control Module ........................ Air Bag Restraint System
Starter Motor ............................................. Starters
Starter Interrupt Relay ................................... Starters
Starter Solenoid .......................................... Starters
Starter Relay ............................................. Starters
Steering Wheel Position Sensor .................... Anti-Lock Brakes
Stoplights ......................................... Exterior Lights
Stoplight Switch ................................ Engine Performance
Cruise Control Systems
Anti-Lock Brakes
Sun Roof ECU ........................................ Power Sun Roof
Sun Roof Motor ...................................... Power Sun Roof
Sun Roof Position Sensor ............................ Power Sun Roof
Taillights ......................................... Exterior Lights
Throttle Position (TP) Sensor ................... Engine Performance\


IN STR UM EN T P A N EL - A N ALO G

1999 D odge P ic ku p R 1500
1999 ACCESSORIES & EQUIPMENT
CHRY - Analog Instrument Panels
Ram Pickup, Ram Van & Ram Wagon
DESCRIPTION & OPERATION
INSTRUMENT CLUSTER
All instrument cluster gauges are air core magnetic type.
Tachometer is optional. All gauges use data transferred on Chrysler
Collision Detection (CCD) bus. Instrument cluster incorporates a
Vacuum Fluorescent Display (VFD) for odometer display.
Brake warning light illuminates when ignition is on and
parking brake is applied. Brake warning light also illuminates if
brake hydraulic system failure occurs during service brake
application. Brake warning light bulb test occurs when ignition switch
is in START position.
Oil pressure warning light illuminates when engine oil
pressure is not sufficient to open oil pressure sending unit switch.
Oil pressure warning light bulb test occurs with ignition switch in
RUN position.
All instrument clusters include these analog gauges:
* Coolant Temperature Gauge
* Fuel Gauge
* Oil Pressure Gauge
* Speedometer
* Voltmeter
Instrument clusters include these indicator lights, if
vehicle is equipped with appropriate option:
* Air Bag
* Anti-Lock Brake System (ABS)
* Brake Warning
* Check Gauges
* Cruise On
* Headlight High Beam
* Low Fuel
* Low Washer Fluid
* CHECK ENGINE
* Overdrive Off
* Rear Wheel Anti-Lock (RWAL)
* Seat Belt Reminder
* Security
* Transmission Oil Temperature (A/T)
* Turn Signal
* Upshift (M/T)
* 4WD
SELF-DIAGNOSTIC SYSTEM
WARNING: Vehicle is equipped with an air bag system. To prevent air
bag deployment, disconnect negative battery cable and wait at
least 2 minutes before servicing instrument cluster. See
appropriate AIR BAG RESTRAINT SYSTEMS article.
CAUTION: When battery is disconnected, vehicle computer and memory

Installation
1) If engine has not been rotated after removing distributor,
go to next step. If engine was rotated after removing distributor,
rotate crankshaft clockwise (viewed from front of engine) until
cylinder No. 1 is at Top Dead Center (TDC) on compression stroke and
timing mark on vibration damper aligns with TDC timing mark on timing
chain cover. Go to next step.
2) Ensure distributor mounting area on cylinder block is
clean. Install NEW "O" ring on distributor if necessary. Apply light
coat of engine oil on "O" ring.
3) Position distributor rotor so it aligns with terminal for
cylinder No. 1 on distributor cap. Install distributor. Ensure
distributor engages with slot in oil pump drive gear. Install hold-
down clamp and distributor hold-down bolt. DO NOT tighten distributor
hold-down bolt at this time.
4) Rotate distributor until distributor rotor aligns with
cylinder No. 1 alignment mark on camshaft position sensor. See Fig. 23
. Tighten distributor hold-down bolt to specification. See TORQUE
SPECIFICATIONS. To install remaining components, reverse removal
procedure.
5) Base ignition timing is nonadjustable. Base ignition
timing and timing advance are controlled by the Powertrain Control
Module (PCM). Distributor position is used to determine the fuel
system synchronization. To check for correct distributor position and
fuel system synchronization, see FUEL SYSTEM SYNCHRONIZATION under
FUEL SYSTEM in ON-VEHICLE ADJUSTMENTS article.
IGNITION COIL
Removal & Installation (Dakota 2.5L)
Ignition coil is located on side of engine, near distributor.
Service procedure is primarily an unbolt and bolt-on procedure.
Tighten ignition coil retaining bolts or nuts to specification. See
TORQUE SPECIFICATIONS.
Removal & Installation (Dakota 3.9L, 5.2L & 5.9L, Durango &
Ram Van/Wagon)
1) Ignition coil is located on front of passenger's side
cylinder head. Disconnect spark plug wires and electrical connector
from ignition coil.
CAUTION: Ignition coil-to-cylinder head mounting bracket bolts hold
the idler pulley for the accessory drive belt, as these bolts
are under tension. If necessary to remove these bolts,
accessory drive belt must be removed first.
2) Remove ignition coil retaining bolts or nuts with ignition
coil from the ignition coil mounting bracket. DO NOT remove ignition
coil-to-cylinder head mounting bracket bolts, as these bolts are under
tension.
3) To install, reverse removal procedure. Tighten ignition
coil retaining bolts or nuts to specification. See TORQUE
SPECIFICATIONS.
Removal & Installation (Ram Pickup 3.9L, 5.2L & 5.9L)
1) On 3.9L, 5.2L and 5.9L with light-duty emissions, ignition
coil is located on front of passenger's side cylinder head. On 5.9L
with heavy-duty emissions, ignition coil is located on top of air
injection pump. On all models, disconnect spark plug wires and
electrical connector from ignition coil.
CAUTION: On 3.9L, 5.2L and 5.9L with light-duty emissions, ignition
coil-to-cylinder head mounting bracket bolts hold the idler

pulley for the accessory drive belt, as these bolts are under
tension. If necessary to remove these bolts, accessory drive
belt must be removed first.
2) Remove ignition coil retaining bolts or nuts with ignition
coil from the ignition coil mounting bracket. On 3.9L, 5.2L and 5.9L
with light-duty emissions, DO NOT remove ignition coil-to-cylinder
head mounting bracket bolts, as these bolts are under tension. On all
applications, to install, reverse removal procedure. Tighten ignition
coil retaining bolts or nuts to specification. See TORQUE
SPECIFICATIONS.
Removal & Installation (Ram Pickup 8.0L)
1) Two separate ignition coils are located above passenger's
side valve cover. Each ignition coil can be serviced separately. On
all ignition coil applications, disconnect spark plug wires and
electrical connector from ignition coil.
2) Remove ignition coil retaining bolts and ignition coil
from ignition coil mounting bracket. To install, reverse removal
procedure. Ensure ignition coil is mounted on ignition coil mounting
bracket with electrical connector facing downward. Tighten ignition
coil retaining bolts to specification. See TORQUE SPECIFICATIONS.
FUEL SYSTEM
FUEL SYSTEM PRESSURE RELEASE
WARNING: Always release fuel pressure before disconnecting any fuel
injection-related component. DO NOT allow fuel to contact
engine or electrical components.
1) Remove fuel cap from fuel tank. Note location of spring
loaded flapper valve inside fuel tank filler tube assembly. Flapper
valve is located just below the fuel cap area on fuel tank filler tube
assembly. Flapper valve is used as a secondary way of sealing the fuel
tank if fuel cap was not properly tightened.
WARNING: When opening flapper valve inside fuel tank filler tube
assembly, ensure a non-metallic object is used to prevent any
sparks.
2) Using a non-metallic object, push flapper valve inside
filler tube assembly downward to release any pressure from the fuel
tank. Ensure all pressure is released from fuel tank.
3) Remove fuel pump relay from Power Distribution Center
(PDC). Fuel pump relay may be identified by label on inside of PDC
cover. See POWER DISTRIBUTION CENTER (PDC) LOCATION table.
4) On all models, start engine and allow engine to idle until
engine stalls. Attempt to restart engine until engine will no longer
run. Turn ignition off.
CAUTION: Ensure steps 1) through 4) are performed before proceeding.
Steps 3) and 4) must be performed to ensure most of the fuel
pressure is released from fuel rails to prevent an excessive
amount of fuel being delivered into the cylinders.
5) Remaining fuel pressure is released by energizing a fuel
injector. Disconnect electrical connector at any fuel injector.
6) Connect jumper wire between one electrical terminal on
fuel injector and positive battery terminal. Connect another jumper
wire on remaining electrical terminal on fuel injector.

  Brake Hoses 


\
\
\
\
\
\
\


 Engine Coolant Level, Hoses & Clamps 


\
\
\
\
\
\
\


 Brake Linings 


\
\
\
\
\
\
\


 Drive Belts 

\
\
\
\
\
\
\



SERVICE 

\b\
\
\
\
\
\
\


 Rotate Tires 


\
\
\
\
\
\
\


 Lubricate Steering Linkage 

\
\
\
\
\
\
\



REPLACE 

\b\
\
\
\
\
\
\


 Engine Oil 


\
\
\
\
\
\
\


 Engine Oil Filter 

\
\
\
\
\
\
\



LUBRICATION SPECIFICATIONS 

\
\b\
\
\
\b\
\
\



Material  Condition  Specification 

\

\
\
\

\
\
\


Engine Oil Ambient Temperature Above 10F SAE 15W-40 

(
1)  (-12C) To Over 30F (-1C)  


\
\
\

\
\


Ambient Temperature Less Than  SAE 10W-30 

0F (-18C) To Over 30F(-1C) 


\
\
\

\
\


Ambient Temperature Less Than  With Block Heater: 

-10F(-23C) Up To 0F (-18C) SAE 10W-30 

  Without Block Heater: 

  SAE 5W-30 

\

\
\
\

\
\
\


Engine  All  50/50 Mixture Of 

Coolant   Distilled Water & 

  Ethylene Glycol 

\

\
\
\

\
\
\


Brake Fluid  All  DOT 3 

\

\
\
\

\
\
\


Steering  All  Mopar Multi-Mileage 

Linkage   Lubricant 

Lubricant   

\
\
\
\
\
\
\


(
1) - SAE 10W-30 engine oil is preferred. Use only API approved 

oil with Starburst Symbol. 

\
\
\
\
\
\
\



FLUID CAPACITIES 

\
\b\
\
\
\b\
\
\



Item  Condition  Specification (1) 

\

\
\
\

\
\
\


Engine Oil  Capacity, Upper Safe Mark  10 Qts. (9.5L) 


\
\
\

\
\


 Capacity, Lower Safe Mark  8 Qts. (7.5L) 

\

\
\
\

\
\
\


Engine  Drained  26 Qts. (24.5L) 

Coolant   

\
\
\
\
\
\
\


(
1) - Capacities are recommended or calculated levels. Always use 

dipstick (if available) to measure level. 
\f
\
\
\
\
\
\
\



\
\
\
\
\
\
\


 Drive Belts 


\
\
\
\
\
\
\


 Water Pump Weep Hole For Blockage 

\
\
\
\
\
\
\



SERVICE 

\b\
\
\
\
\
\
\


 Rotate Tires 


\
\
\
\
\
\
\


 Lubricate Steering Linkage 


\
\
\
\
\
\
\


 Clean Fuel Strainer 

\
\
\
\
\
\
\



REPLACE 

\b\
\
\
\
\
\
\


 Engine Oil 


\
\
\
\
\
\
\


 Engine Oil Filter 


\
\
\
\
\
\
\


 Engine Coolant 


\
\
\
\
\
\
\


 Fuel Filter 


\
\
\
\
\
\
\


 Transfer Case Fluid 

\
\
\
\
\
\
\



LUBRICATION SPECIFICATIONS 

\
\b\
\
\
\b\
\
\



Material  Condition  Specification 

\

\
\
\

\
\
\


Engine Oil Ambient Temperature Above 10F SAE 15W-40 

(
1)  (-12C) To Over 30F (-1C)  


\
\
\

\
\


Ambient Temperature Less Than  SAE 10W-30 

0F (-18C) To Over 30F(-1C) 


\
\
\

\
\


Ambient Temperature Less Than  With Block Heater: 

-10F(-23C) Up To 0F (-18C) SAE 10W-30 

  Without Block Heater: 

  SAE 5W-30 

\

\
\
\

\
\
\


Engine  All  50/50 Mixture Of 

Coolant   Distilled Water & 

  Ethylene Glycol 

\

\
\
\

\
\
\


Brake Fluid  All  DOT 3 

\

\
\
\

\
\
\


Steering  All  Mopar Multi-Mileage 

Linkage   Lubricant 

Lubricant   

\

\
\
\

\
\
\


Transfer Case All  ATF+2 Type 7176 

Fluid   Or DEXRON III ATF 

\
\
\
\
\
\
\


(
1) - SAE 10W-30 engine oil is preferred. Use only API approved 

oil with Starburst Symbol. 

\
\
\
\
\
\
\



FLUID CAPACITIES 

\
\b\
\
\
\b\
\
\



Item  Condition  Specification (1) 

\

\
\
\

\
\
\


Engine Oil  Capacity, Upper Safe Mark  10 Qts. (9.5L) 


\
\
\

\
\


 Capacity, Lower Safe Mark  8 Qts. (7.5L) 

 VERIFY 

\b\
\
\
\
\
\
\



Last Major Service Was Performed. 

\
\
\
\
\
\
\



INSPECT 

\b\
\
\
\
\
\
\


 Exhaust System 


\
\
\
\
\
\
\


 Brake Hoses 


\
\
\
\
\
\
\


 Engine Coolant Level, Hoses & Clamps 


\
\
\
\
\
\
\


 Brake Linings 


\
\
\
\
\
\
\


 Drive Belts 

\
\
\
\
\
\
\



SERVICE 

\b\
\
\
\
\
\
\


 Rotate Tires 


\
\
\
\
\
\
\


 Lubricate Steering Linkage 

\
\
\
\
\
\
\



REPLACE 

\b\
\
\
\
\
\
\


 Engine Oil 


\
\
\
\
\
\
\


 Engine Oil Filter 

\
\
\
\
\
\
\



LUBRICATION SPECIFICATIONS 

\
\b\
\
\
\b\
\
\



Material  Condition  Specification 

\

\
\
\

\
\
\


Engine Oil Ambient Temperature Above 10F SAE 15W-40 

(
1)  (-12C) To Over 30F (-1C)  


\
\
\

\
\


Ambient Temperature Less Than  SAE 10W-30 

0F (-18C) To Over 30F(-1C) 


\
\
\

\
\


Ambient Temperature Less Than  With Block Heater: 

-10F(-23C) Up To 0F (-18C) SAE 10W-30 

  Without Block Heater: 

  SAE 5W-30 

\

\
\
\

\
\
\


Engine  All  50/50 Mixture Of 

Coolant   Distilled Water & 

  Ethylene Glycol 

\

\
\
\

\
\
\


Brake Fluid  All  DOT 3 

\

\
\
\

\
\
\


Steering  All  Mopar Multi-Mileage 

Linkage   Lubricant 

Lubricant   

\
\
\
\
\
\
\


(
1) - SAE 10W-30 engine oil is preferred. Use only API approved 

oil with Starburst Symbol. 

\
\
\
\
\
\
\



FLUID CAPACITIES 

\
\b\
\
\
\b\
\
\



Item  Condition  Specification (1) 

\

\
\
\

\
\
\


Engine Oil  Capacity, Upper Safe Mark  10 Qts. (9.5L) 


\
\
\

\
\


 Capacity, Lower Safe Mark  8 Qts. (7.5L)