diesel DODGE RAM 1999 Service Workshop Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 880 of 1691
in the ENGINE MECHANICAL section.
Fig. 9: Valve Adjustment - Step 2 of 2 (Diesel)
Courtesy of Chrysler Corp.
NOTE: For more information regarding 5.9L Diesel engine service
refer to the 5.9L V8 TURBO DIESEL - VIN [D] article.
in the ENGINE MECHANICAL section.
Fig. 10: Water Separator (Diesel)
Courtesy of Chrysler Corp.
NOTE: For more information regarding 5.9L Diesel engine service
Page 881 of 1691
![DODGE RAM 1999 Service Workshop Manual refer to the 5.9L V8 TURBO DIESEL - VIN [D] article.
in the ENGINE MECHANICAL section.
Drain fuel/water separator by pushing up on the valve
located on the bottom](/img/12/56915/w960_56915-880.png "DODGE RAM 1999 Service Workshop Manual refer to the 5.9L V8 TURBO DIESEL - VIN [D] article.
in the ENGINE MECHANICAL section.
Drain fuel/water separator by pushing up on the valve
located on the bottom")
refer to the 5.9L V8 TURBO DIESEL - VIN [D] article.
in the ENGINE MECHANICAL section.
Drain fuel/water separator by pushing up on the valve
located on the bottom of the fuel filter until clear fuel
is visible. Drain fuel into a container and follow proper
disposal procedures.
CAUTION: DO NOT drain fuel/water separator when engine is running or
hot. Allow engine to cool before draining. Verify that the
WATER IN FUEL light on instrument panel is OFF.
ADDITIONAL SERVICE INFORMATION - CNG MODELS
Fig. 11: Locating CNG Components
Courtesy of Chrysler Corp.
Page 886 of 1691
Fig. 17: CNG Identification Label Locations
Courtesy of Chrysler Corp.
Fig. 18: Tank Test Date Label Location
Courtesy of Chrysler Corp.
LUBRICATION SPECIFICATIONS - DIESEL
Page 887 of 1691
![DODGE RAM 1999 Service Workshop Manual LUBRICATION SPECIFICATIONS TABLE - DIESEL \
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LUBRICATION SPECIFICATIONS TABLE - DIESEL \
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Material Condition Specification
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Engine Oil Ambient Temperature Above 10\bF SAE 15W-40
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1) (-12\bC) To Over 30\bF (-1\bC)
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Ambient Temperature Less Than SAE 10W-30
0\bF (-18\bC) To Over 30\bF(-1\bC)
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Ambient Temperature Less Than With Block Heater:
-10\bF(-23\bC) Up To 0\bF (-18\bC) SAE 10W-30
Without Block Heater:
SAE 5W-30
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Engine All 50/50 Mixture Of
Coolant Distilled Water &
Ethylene Glycol
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Brake Fluid All DOT 3
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Automatic All ATF+2 Type 7176
Transmission
Fluid
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Transfer Case All ATF+2 Type 7176
Fluid Or DEXRON III ATF
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Manual All 75W-90 Synthc. API GL4
Transmission
Fluid
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Steering All Mopar Multi-Mileage
Linkage Lubricant
Lubricant
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Wheel Bearing All High Temperature Multi-
Grease -Purporse EP Grease
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Rear Axle All Mopar Hypoid Lubricant
Lubricant SAE 80W-90
(
2) GL-5 Gear Lube
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4x4 Front All Mopar Hypoid Lubricant
Axle SAE 80W-90
Lubricant GL-5 Gear Lube
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Power All Mopar Power Steering
Steering Fluid Or Equivalant
Fluid (
3) Petroleum Based
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Clutch All Multipurpose Grease
Linkage NLGI Grade 2 E.P.
Lubricant
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A/C All R-134a
Refrigerant
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A/C All Polyalkalene Glycol
Refrigerant SP10 PAG
Oil Refrigerant Oil
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Page 888 of 1691
(
1) - SAE 10W-30 engine oil is preferred for use in all Dodge
trucks. Use only API approved oil with Starburst Symbol.
(
2) - Axles with Limited-Slip Differentials require the use of
a 5% Friction Modifier, such as Mopar Gear Oil Additive
Friction Modifier.
(
3) - Never add gear oil, automatic transmission fluid or
hydroboost power steering fluid.
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FLUID CAPACITIES - DIESEL
FLUID CAPACITIES TABLE - DIESEL \
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Item Condition Specification (1)
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Engine Oil Capacity, Upper Safe Mark 10 Qts. (9.5L)
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Capacity, Lower Safe Mark 8 Qts. (7.5L)
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Engine Drained 26 Qts. (24.5L)
Coolant
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Automatic 46RE: Dry Fill 17 Qts. (16L)
Transmission
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Fluid 47RE: Dry Fill 17 Qts. (16L)
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Manual NV4500 4 Qts. (3.8L)
Transmission
Fluid
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Rear Axle DANA 70 Model 267 (2WD) 7 Pts. (3.3L)
Lubricant
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DANA 70 Model 267 (4WD) 7.8 Pts. (3.6L)
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DANA 80 Model 286 (2WD) 6.8.Pts. (3.2L)
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DANA 80 Model 286 (4WD) 10.1 Pts. (4.8L)
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Rear Axle Model 267 (2WD) 7 Pts. (3.3L)
Limited Slip
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Differential Model 267 (4WD) 7.8 Pts. (3.6L)
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Model 286 (2WD) 6.8 Pts. (3.2L)
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Model 286 (4WD) 10.1 Pts. (4.8L)
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Front Axle Model 248 7.6 Pts. (3.6L)
Lubricant
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Transfer Case NV241 HD 6.5 Pts. (3.1L)
Fluid
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Power Take NV021 4.6 Pts. (2.1L)
Off Adapter
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Power Drained 2.7 Pts. (1.3L)
Steering
Fluid
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A/C Charge Capacity 32 Oz. (.9Kg)
Refrigerant
Page 894 of 1691
been submerged in water. Water can enter through the axle
vent hole and contaminate the lubricant.
BATTERY WARNING
WARNING: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure.
WARNING: Batteries produce flammable hydrogen gas. Keep flames and
sparks away from the battery or and explosion may occur.
Never smoke when working in the vicinity of the battery.
WARNING: When checking or servicing the battery, disconnect the
negative cable. Be careful not to cause a short circuit by
allowing metal objects to contact the battery posts and the
vehicle at the same time.
REPLACING BLOWN FUSES
CAUTION: Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical
system. Be sure to use fuse with the correct indicated
amperage rating. The use of an incorrect amperage rating fuse
may result in a dangerous electrical system overload.
BRAKE PAD WEAR INDICATOR
Indicator will cause a squealing or scraping noise, warning
that brake pads need replacement.
BRAKE HOSES
WARNING: Worn brake hoses can burst and cause brake failure. If
any sign of cracking, scuffing, or worn spots are found,
replace the brake hoses immediately.
BRAKE FLUID
WARNING: The use of incorrect fluid in the brake system may cause
damage to components. DO NOT use any fluid other than DOT-3
brake fluid. DO NOT use reclaimed fluid or fluid that has
been stored in old or open containers. It is essential that
foreign particles and other liquids are kept out of the
brake fluid reservoir.
CATALYTIC CONVERTER
CAUTION: Continued operation of vehicle with a severe malfunction
could cause converter to overheat, resulting in possible
damage to converter and vehicle.
COOLANT
CAUTION: To avoid possible damage to vehicle use only ethylene-glycol
based coolants with a mixture ratio from 50-70% anti-freeze.
DO NOT use 100% anti-freeze as it will cause the formation
of cooling system deposits.
DIESEL FUEL ANTI-FUNGAL ADDITIVES
Page 895 of 1691
CAUTION: If fuel contamination due to fungi or other microorganisms is
suspected a fuel additive with a biocide may be used. Follow
the manufacturers dosage as recommended on product label. Use
biocides ONLY when necessary, excessive use can may cause
other fuel system problems.
DIESEL FUEL CONTAMINATION
WARNING: Diesel fuel system may be contaminated with fungi or other
microorganisms. Keep contaminated fuel away from open skin
cuts or sores to prevent skin irritation or infection.
DIESEL FUEL REQUIREMENTS
CAUTION: All diesel engines have been developed to take advantage of
the high energy content of No. 2 diesel fuel or No. 2
climatized-diesel fuels. It also operates on No. 1-diesel
fuels if temperatures are expected to be extended arctic
conditions -10
\bF (-23\bC).
WARNING: Do NOT use alcohol or gasoline as a fuel blending agent. They
can be unstable under certain conditions and hazardous or
explosive when mixed with diesel fuel.
ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
WARNING: Many solid state electrical components can be damaged by
static electricity (ESD). Some will display a warning label,
but many will not. Discharge personal static electricity by
touching a metal ground point on the vehicle prior to
servicing any ESD sensitive component.
ENGINE OIL
CAUTION: Never use non-detergent or straight mineral oil.
ENGINE OIL FILTER (CARTRIDGE TYPE)
CAUTION: Use of Mopar Oil Filter Cartridge (P/N 04746914) is
RECOMMENDED. The engine oil filter cartridge should be
changed at every engine oil change. Use the same type oil
that will be used in the engine.
FUEL SYSTEM SERVICE
WARNING: Relieve fuel system pressure prior to servicing any fuel
system component (fuel injection models).
HALOGEN BULBS
WARNING: Halogen bulbs contain pressurized gas which may explode if
overheated. DO NOT touch glass portion of bulb with bare
hands. Eye protection should be worn when handling or working
around halogen bulbs.
RADIATOR CAP
CAUTION: Always disconnect the fan motor when working near the
radiator fan. The fan is temperature controlled and could
start at any time even when the ignition key is in the OFF
position. DO NOT loosen or remove radiator cap when cooling
system is hot.
Page 896 of 1691
RADIATOR FAN
WARNING: Keep hands away from radiator fan.
STARTING FLUID USE (TURBO DIESEL)
WARNING: DO NOT USE starting fluids (ether) or flammable liquids to
aid the starting of a Cummins Turbo-Diesel. NEVER pour diesel
fuel, flammable liquids or starting fluids into the air
cleaner canister, air intake or turbocharger housing in an
attempt to start the vehicle. A flash fire may result causing
personal injury.
TIRE CHAINS
CAUTION: Do NOT install tire chains or traction devices on front
wheels of 4x4 models with tires larger than P215/75R15. Do
NOT install tire chains or traction devices on rear wheels of
4x4 models with tires larger than P235/75R15. These tires are
too large for sufficient body clearance with chains or other
traction devices. Tire chains are not allowed on 4x2 vehicles
equipped with P235/70R15 tires or 4x4 vehicles equipped with
31 x 10.50R15 tires.
CAUTION: Do NOT drive for a prolonged period of time on dry pavement.
TURBOCHARGED MODELS (TURBO-DIESEL)
CAUTION: Do not race engine immediately after starting. When
stopping engine, allow engine to idle for approximately 60
seconds before shutting it off. Failure to do so may cause
turbocharger damage due to lack of oil flowing to
the turbocharger bearings.
WARRANTY INFORMATION
CAUTION: Due to the different warranties offered in various regions
and the variety of after-market extended warranties
available, please refer to the warranty package that came
with the vehicle to verify all warranty options.
FUSES & CIRCUIT BREAKERS
Page 922 of 1691
N - R EM OVE/IN STA LL/O VER HAU L - D IE SEL
1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Removal, Overhaul & Installation - Trucks - Diesel
Ram Pickup
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.
INTRODUCTION
Removal, overhaul and installation procedures are covered in
this article. If component removal and installation is primarily an
unbolt and bolt-on procedure, only a torque specification may be
furnished.
COMPUTERIZED ENGINE CONTROLS
POWERTRAIN CONTROL MODULE (PCM)
Removal & Installation
1) Disconnect negative battery cables. Disconnect electrical
connectors from PCM. The PCM is located at passenger's side rear
corner of engine compartment, on the firewall. See Fig. 1. Remove
mounting bolts and PCM.
2) To install, reverse removal procedure. Tighten mounting
bolts to specification. See TORQUE SPECIFICATIONS.
Fig. 1: Locating Powertrain Control Module (PCM)
Courtesy of Chrysler Corp.
AIR INDUCTION SYSTEMS
Page 924 of 1691
CAUTION: If turbocharger failure exists, intercooler must be cleaned.
See INTERCOOLER under AIR INDUCTION SYSTEMS.
Removal
1) Disconnect negative battery cables. Disconnect air inlet
tube and exhaust pipe from turbocharger. Disconnect intercooler inlet
duct from turbocharger. See Fig. 2.
2) Disconnect and plug turbocharger oil supply line and
turbocharger oil drain line at turbocharger. Remove turbocharger
retaining nuts, turbocharger and gasket from exhaust manifold. Plug
all air intake openings.
Installation
1) Apply anti-seize compound on turbocharger mounting studs.
Using NEW gasket, install turbocharger. Install and tighten
turbocharger retaining nuts to specification. See TORQUE
SPECIFICATIONS.
2) Using NEW gasket, install turbocharger oil drain line on
turbocharger. Install and tighten turbocharger oil drain line bolts to
specification. See TORQUE SPECIFICATIONS.
CAUTION: Turbocharger must be pre-lubricated by pouring clean engine
oil in turbocharger oil supply line fitting on turbocharger
before starting the engine.
WARNING: DO NOT rotate turbine wheel in turbocharger with your finger,
as sharp edges may exist.
3) Pour 3 ozs. (60 cc) of clean engine oil into turbocharger\
oil supply line fitting on turbocharger while using soft object to
rotate turbine wheel in turbocharger. This must be done to pre-
lubricate the turbocharger.
4) Install turbocharger oil supply line on turbocharger and
tighten nut to specification. See TORQUE SPECIFICATIONS. To install
remaining components, reverse removal procedure. Tighten bolts/nuts to
specification. See TORQUE SPECIFICATIONS.
TURBOCHARGER WASTEGATE ADJUSTMENT
NOTE: For turbocharger wastegate adjustment, see CONTROL ROD
ADJUSTMENT under TURBOCHARGER WASTEGATE in ON-VEHICLE
ADJUSTMENTS - DIESEL article.
ENGINE SENSORS & SWITCHES
ENGINE COOLANT TEMPERATURE SENSOR
Removal & Installation
1) Engine coolant temperature sensor is located at front of
cylinder head near thermostat. See Fig. 3.
2) Partially drain cooling system until coolant level is
below the cylinder head. Disconnect ECT sensor electrical connector.
Remove ECT sensor from cylinder head. Discard "O" ring. To install,
reverse removal procedure. Use new "O" ring.
CRANKSHAFT POSITION SENSOR (CKP)
NOTE: Crankshaft Position (CKP) sensor may be referred to as engine\
speed sensor.
Removal & Installation
1) CKP sensor is located on left rear side of engine block