steering 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 473 of 1691
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.
Some conditions indicate that a service or part replacement
is suggested because the part is close to the end of its useful life
or addresses a customer's need, convenience or request. If a
customer's vehicle has one of these conditions, the procedure may be
only to suggest service.
Page 511 of 1691
ELE C TR IC AL C O M PO NEN T L O CATO R
1999 D odge P ic ku p R 1500
1999 ELECTRICAL COMPONENT LOCATION
Chrysler Motors Electrical Component Location
Dodge; Ram Pickup
SAFETY PRECAUTION
WARNING: When working on vehicles equipped with Supplemental Restraint
System (SRS), never apply electrical voltage to the system.
This could cause the SRS (air bag) to be deployed.
BUZZERS, RELAYS & TIMERS
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Component Component Location \
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A/C Compressor Clutch Relay On power distribution center.
Automatic Shut Down Relay On power distribution center.
Blower Motor Relay On power distribution center.
Central Timer Module Left side of dash, inboard of
steering column opening.
Combination Flasher Left side of dash, on
junction block.
Engine Starter Motor Relay On power distribution center.
Fog Lamp Relay On power distribution center.
Fuel Heater Relay (Diesel) On power distribution center.
Fuel Pump Relay On power distribution center.
Horn Relay On power distribution center.
Intake Air Heater Relay No. 1
(Diesel) On left inner fender, below
left battery.
Intake Air Heater Relay No. 2
(Diesel) On left inner fender, below
left battery.
Quad High Beam Relay On power distribution center.
Radio Choke Relay Behind center of dash, on
support.
Security Relay On power distribution center.
Trailer Tow Relay On power distribution center.
Transmission Control Relay On power distribution center.
Wiper Motor Relay On power distribution center.
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Page 512 of 1691
![DODGE RAM 1999 Service Workshop Manual CIRCUIT PROTECTION DEVICES
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CIRCUIT PROTECTION DEVICES
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Component Component Location \
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Circuit Breakers In junction block.
Junction Block Left end of dash.
Power Distribution Center In engine compartment, on left
inner fender panel, near
battery.
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CONTROL UNITS
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Air Bag Control Module Behind lower center of dash.
Controller Anti-Lock Brake (4WABS) Engine compartment, mounted on\
top of hydraulic control unit.
Controller Anti-Lock Brake (RWAL) In engine compartment, on left\
front inner fender.
Daytime Running Lamp (DRL) Module In engine compartment, on left\
inner fender panel.
Engine Control Module (Diesel) On left side of engine, behind\
fuel filter.
Fuel Pump Module Top of fuel tank.
Integrated Electronic Module Left side of dash, inboard of
steering column opening.
Powertrain Control Module (PCM) In engine compartment, on
right side of firewall.
Seat Belt Control Module Under front seat center
cushion.
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MOTORS
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Component Component Location \
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Blower Motor Behind right side of dash.
Fuel Injection Pump (Diesel) On left side of engine, on
rear of timing gear housing.
Fuel Transfer Pump (Diesel) On left side of engine, below
and rearward of fuel filter.
Page 523 of 1691
Engine Oil Pressure Sensor
(8.0L) Near oil filter.
Front Wheel Speed Sensors On left and right steering
knuckles.
Heated Oxygen Sensor (HO2S)
(Downstream) (3.9L) Near outlet end of catalytic\
converter.
Heated Oxygen Sensor (HO2S)
(Downstream) (5.2L) Near outlet end of catalytic\
converter.
Heated Oxygen Sensor (HO2S)
(Left Upstream) (5.9L Heavy Duty) In left exhaust manifold
downpipe.
Heated Oxygen Sensor (HO2S)
(Left Upstream) (8.0L) In left exhaust manifold
downpipe.
Heated Oxygen Sensor (HO2S)
(Post-Catalyst) (5.9L Medium Duty) Near outlet end of catalytic\
converter.
Heated Oxygen Sensor (HO2S)
(Post-Catalyst) (8.0L California) In exhaust pipe, rear of
catalytic converter.
Heated Oxygen Sensor (HO2S)
(Pre-Catalyst) (5.9L Medium Duty) At inlet of catalytic
converter.
Heated Oxygen Sensor (HO2S)
(Pre-Catalyst) (8.0L California) At inlet of catalytic
converter.
Heated Oxygen Sensor (HO2S)
(Right Upstream) (5.9L Heavy Duty) In right exhaust manifold
downpipe.
Heated Oxygen Sensor (HO2S)
(Right Upstream) (8.0L) In right exhaust manifold
downpipe.
Heated Oxygen Sensor (HO2S)
(Upstream) (3.9L) At inlet of catalytic
converter.
Heated Oxygen Sensor (HO2S)
(Upstream) (5.2L) At inlet of catalytic
converter.
Page 544 of 1691
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.
Page 617 of 1691
EN G IN E C O OLIN G S PEC IF IC ATIO NS
1999 D odge P ic ku p R 1500
1998-99 ENGINE COOLING
CHRY - Specifications - All Models
1998 Talon
1998-99 Avenger, Breeze, Caravan, Cirrus, Concorde, Dakota,
Durango, Intrepid, Neon, Ram Pickup, Ram Van/Wagon, Sebring
Convertible, Sebring Coupe, Stratus, Town & Country, Voyager
1999 LHS, 300M
BELT ADJUSTMENT
NOTE: For belt routing on models not covered in this article,
information was not available. See underhood label for proper
belt routing.
Belts should be adjusted to proper tension using belt tension
gauge. See appropriate BELT ADJUSTMENT SPECIFICATIONS table. Some
models may be equipped with an automatic belt tensioner. Ensure
serpentine belts are routed properly. See Figs. 5 through 14.
4-CYLINDER BELT ADJUSTMENT SPECIFICATIONS - CARS
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Application New Belt (1) Used Belt
Lbs. (kg) Lbs. (kg\
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Avenger & Sebring Coupe
2.0L
Generator ................... 110-160 (50-73) .. 90-110 (41-50\
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Power Steering
With A/C .................. 137-159 (62-72) .. 93-115 (42-52\
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Without A/C ............... 110-160 (50-73) .. 90-110 (41-50\
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Breeze, Cirrus & Stratus
2.0L & 2.4L
A/C & Generator .................. 150 (68) ............ 80 (36\
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Power Steering .................. 130 (59) ............ 80 (36\
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Neon
2.0L (DOHC & SOHC)
A/C & Pwr. Steering ............. 135 (61) ........... 100 (45\
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Generator ....................... 135 (61) ........... 100 (45\
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Sebring Convertible
2.4L .......................... 150 (68) ............ 80 (36\
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Talon
2.0L Non-Turbo
Generator ................... 110-160 (50-73) .. 90-110 (41-50\
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Power Steering
With A/C .................. 137-159 (62-72) .. 93-115 (42-52\
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Without A/C ............... 110-160 (50-73) .. 90-110 (41-50\
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2.0L Turbo
A/C ........................... 86-99 (39-45) ... 57-75 (26-34\
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Generator ..................... 110-154 (50-70) ........ 88 (40\
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Power Steering ............... 110-154 (50-70) .. 77-92 (35-42\
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( 1) - Belt is considered used after 15 minutes of service.
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V6 BELT ADJUSTMENT SPECIFICATIONS - CARS \
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Application New Belt (1) Used Belt
Lbs. (kg) Lbs. (kg\
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Page 618 of 1691
![DODGE RAM 1999 Service Workshop Manual Avenger & Sebring Coupe
2.5L
A/C ......................... 110-132 (50-60) ... 66-86 (30-39\
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Generator & P/S ............. 143-187 (65-85) .. 99-121 (45-55\
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Cirrus & Stratus 2.5L](/img/12/56915/w960_56915-617.png "DODGE RAM 1999 Service Workshop Manual Avenger & Sebring Coupe
2.5L
A/C ......................... 110-132 (50-60) ... 66-86 (30-39\
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Generator & P/S ............. 143-187 (65-85) .. 99-121 (45-55\
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Cirrus & Stratus 2.5L")
Avenger & Sebring Coupe
2.5L
A/C ......................... 110-132 (50-60) ... 66-86 (30-39\
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Generator & P/S ............. 143-187 (65-85) .. 99-121 (45-55\
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Cirrus & Stratus 2.5L
A/C & Generator ................. 150 (68) ............. 80 (36\
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Power Steering .................. 130 (59) ............. 80 (36\
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Concorde, Intrepid, LHS & 300M
2.7L
All Belts ................... 180-200 (78-91) ........ 120 (54\
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3.2L & 3.5L
A/C ......................... 140-160 (64-73) ........ 120 (54\
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Generator & Power Steering ..... 180-200 (78-91) ........ 120 (54\
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Sebring Convertible
2.5L .......................... 150 (68) ............ 80 (36\
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(1) - Belt is considered used after 15 minutes of service.
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BELT ADJUSTMENT SPECIFICATIONS - TRUCKS \
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Application New Belt (1) Used Belt
Lbs. (kg) Lbs. (kg\
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Dakota & Durango
2.5L ........................ 180-200 (82-91) .. 140-160 (64-73\
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3.9L, 5.2L & 5.9L ................. ( 2) .................... ( 2)
FWD Vans
Caravan & Voyager
2.4L
A/C & Generator .............. 190 (86) ............ 115 (52\
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Power Steering ............... 140 (64) ............. 90 (41\
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3.0L
A/C .......................... 150 (68) ............. 80 (36\
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Generator & P/S ................ ( 2) .................... ( 2)
3.3L & 3.8L ...................... ( 2) .................... ( 2)
Town & Country
3.3L & 3.8L ...................... ( 2) .................... ( 2)
Ram Pickup & Ram Van/Wagon
All Engines ....................... ( 2) .................... ( 2)
( 1) - Belt is considered used after 15 minutes of service.
( 2) - Automatic belt tensioner is used. Belt tension adjustment is not
required.
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Fig. 1: Belt Routing (2.0L Avenger, Sebring Coupe & Talon Without
Turbo)
Courtesy of Chrysler Corp.
Page 633 of 1691
Fig. 2: Identifying Retainer Type Fuel Line Disconnect Fittings
Courtesy of Chrysler Corp.
ENGINE
Removal (Ram Van/Wagon)
1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect negative battery cable. Drain cooling system and engine
oil. Remove and discard oil filter.
2) Remove engine cover, air cleaner and oil dipstick.
Discharge A/C system (if equipped) using approved refrigerant
recovery/recycling equipment. Disconnect A/C lines at condenser, and
plug openings. Remove A/C compressor. Disconnect fan shroud.
3) Remove front bumper, grille and support brace. Disconnect
coolant hoses. Remove radiator, condenser and support as an assembly.
4) Remove upper fan shroud. Remove power steering pump with
hoses attached, and set aside. Remove air pump, spark plug wires and
distributor cap. Disconnect necessary electrical wiring, coolant hoses
and vacuum hoses. Disconnect fuel lines. See FUEL LINE DISCONNECT
Page 634 of 1691
FITTINGS. Remove air cleaner, throttle body, drive belts, generator,
fan and fan pulley. Remove lower fan shroud.
CAUTION: When removing engine, DO NOT lift engine by intake manifold.
5) Remove intake manifold. See INTAKE MANIFOLD. Raise and
support vehicle. Remove starter. Remove exhaust pipe and heat shields.
Disconnect transmission shift linkage. Remove crank sensor.
6) On A/T models, remove transmission inspection cover. Mark
torque converter-to-flexplate position for installation reference.
Remove torque converter-to-flexplate bolts. On M/T models, disconnect
clutch release mechanism at clutch housing.
7) Attach engine hoist to cylinder heads (at intake manifold
flanges). On all models, support transmission using a floor jack.
Remove transmission or clutch housing-to-cylinder block bolts. Remove
engine mount bolts. Remove engine out front of vehicle.
Installation
To install, reverse removal procedure. Tighten bolts/nuts to
specification. See TORQUE SPECIFICATIONS table. On A/T models, ensure
reference marks on torque converter and flexplate are aligned.
Evacuate and charge A/C system.
Removal ( Dakota 2WD, Durango 2WD, Grand Cherokee & Ram
Pickup)
1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect and remove battery. On all except Pickup, scribe hood
hinges for installation reference and remove hood.
2) On all models, drain cooling system. Disconnect coolant
hoses. Remove radiator, fan and shroud. Discharge A/C system (if
equipped) using approved refrigerant recovery/recycling equipment.
Disconnect A/C lines, and plug openings. On Pickup, remove upper core
support, transmission cooler and A/C condenser. On all models, remove
belt, air cleaner, vacuum lines, distributor cap and wiring.
3) Disconnect necessary electrical wiring. Disconnect fuel
lines. See FUEL LINE DISCONNECT FITTINGS. Remove throttle body and
linkage. Remove intake manifold. Remove starter, generator, charcoal
canister and horns. Disconnect power steering hoses (if equipped).
Raise and support vehicle. Drain oil. Disconnect exhaust pipe at
exhaust manifold.
4) On A/T models, remove transmission housing inspection
plate. Mark torque converter-to-flexplate position for installation
reference. Remove torque converter-to-flexplate bolts. Remove bracket
for transmission cooler lines.
NOTE: It may be necessary to remove manual transmission if
transmission cannot be supported using floor jack.
5) On M/T models, disconnect clutch release mechanism at
clutch housing. On all models, support transmission using a floor
jack. Remove transmission or clutch housing-to-cylinder block bolts.
Install engine lifting fixture, and attach chain.
CAUTION: When removing engine, DO NOT lift engine by intake manifold.
6) On Ram Pickup and Grand Cherokee, remove front engine
mount bolts. Remove engine from vehicle. On Dakota 2WD and Durango 2WD
models, remove front engine mount through-bolts. See Fig. 3. Remove
engine from vehicle.
Installation
To install, reverse removal procedure. Tighten bolts/nuts to
specification. See TORQUE SPECIFICATIONS table. On A/T models, ensure
Page 635 of 1691
reference marks on torque converter and flexplate are aligned.
Evacuate and charge A/C system.
Removal (Durango 4WD & Dakota 4WD)
1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect and remove battery. Scribe hood hinges for installation
reference and remove hood.
2) Drain cooling system. Disconnect coolant hoses. Remove
radiator, fan and shroud. Discharge A/C system (if equipped) using
approved refrigerant recovery/recycling equipment. Disconnect A/C
lines, and plug openings. Remove air cleaner, vacuum lines,
distributor cap and wiring.
3) Disconnect necessary electrical wiring. Disconnect fuel
lines. See FUEL LINE DISCONNECT FITTINGS. Disconnect accelerator
linkage. Remove throttle body. Remove starter and generator.
Disconnect power steering hoses. Raise and support vehicle. Drain oil.
Disconnect exhaust pipe at exhaust manifold.
NOTE: Engine, transmission and front axle are connected and
supported with insulators and brackets. See Fig. 3.
4) On left side, remove 2 bolts attaching differential pinion
nose bracket-to-bellhousing bolts. Remove pinion nose bracket-to-
adapter bolts (located on top of differential, near pinion). Separate
engine from engine mount by removing engine mount through-bolt and nut
located on top of engine mount.
5) On right side, remove 2 axle-to-bracket bolts and bracket-
to-bellhousing bolt. Separate engine from engine mount by removing
engine mount through-bolt and nut located on top of engine mount.
Remove engine from vehicle.