warning DODGE RAM 1999 Service Workshop Manual

Fig. 2: Identifying PCM Connector Terminals
Courtesy of Chrysler Corp.
REMOVAL & INSTALLATION
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
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.
INSTRUMENT CLUSTER
Removal & Installation (Ram Pickup)

MAIN TE N AN CE IN FO RM ATIO N

1999 D odge P ic ku p R 1500
1997-99 MAINTENANCE
Chrysler Motors Maintenance Information
Dodge: Ram Pickup R1500
Ram Pickup R2500
Ram Pickup R3500
* PLEASE READ THIS FIRST *
Before preforming maintenance on vehicle, ensure that all
cautions and warnings have been observed to prevent vehicle damage or
personal injury. See CAUTIONS & WARNINGS.
NOTE: For scheduled maintenance intervals and the related fluid
capacities, fluid specifications and labor times for major
service intervals, see SCHEDULED SERVICES article below:
R1500
* SCHEDULED SERVICES - NORMAL SERVICE (GAS)
* SCHEDULED SERVICES - SEVERE SERVICE (GAS)
* SCHEDULED SERVICES - NORMAL SERVICE (DIESEL)
* SCHEDULED SERVICES - NORMAL SERVICE (DIESEL)
R2500
* SCHEDULED SERVICES - NORMAL SERVICE (GAS)
* SCHEDULED SERVICES - SEVERE SERVICE (GAS)
* SCHEDULED SERVICES - NORMAL SERVICE (GAS - MD)
* SCHEDULED SERVICES - SEVERE SERVICE (GAS - MD)
* SCHEDULED SERVICES - NORMAL SERVICE (DIESEL)
* SCHEDULED SERVICES - NORMAL SERVICE (DIESEL)
R3500
* SCHEDULED SERVICES - NORMAL SERVICE (GAS - MD)
* SCHEDULED SERVICES - SEVERE SERVICE (GAS - MD)
* SCHEDULED SERVICES - NORMAL SERVICE (DIESEL)
* SCHEDULED SERVICES - NORMAL SERVICE (DIESEL)
Warranty information and specifications for fluid
capacities, lubrication specifications, wheel and tire size,
and battery type are covered in this article.
MODEL IDENTIFICATION
VIN LOCATION
The Vehicle Identification Number (VIN) is located on the
left side of the dash panel at the base of the windshield. The VIN
chart explains the code characters.
VIN CODE ID EXPLANATION

BR3500 (8 Stud Dual Wheel)........................ 145 (195)








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BATTERY SPECIFICATIONS
Vehicle is factory equipped with a maintenance free battery.
The top of the battery is permanently sealed, and water never has to
be added, and periodic maintenance is not required either. But,
periodically check the battery terminals and battery hold-down bracket
for corrosion. Replace with a battery of the same group number as
shown on original battery's label.
CAUTION: 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. See COMPUTER
RELEARN PROCEDURES article in the GENERAL INFORMATION
section.
CAUTIONS & WARNINGS
SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG)
NOTE: See the AIR BAGS article in the ACCESSORIES/SAFETY EQUIPMENT
Section.
Modifications or improper maintenance, including incorrect
removal and installation of the Supplemental Restraint System (SRS),
can adversely affect system performance. DO NOT cover, obstruct or
change the steering wheel horn pad in any way, as such action could
cause improper function of the system. Use only plain water when
cleaning the horn pad. Solvents or cleaners could adversely affect the
air bag cover and cause improper deployment of the system.
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all warnings and service precautions. See
appropriate AIR BAGS article in ACCESSORIES/SAFETY EQUIPMENT.
WARNING: Any maintenance performed on or near the components of the
SRS must be performed only by an authorized dealer.
Do not permit anyone else to service, inspect maintain, or
service any SRS components or wiring. Similarly, no part of
the SRS should ever be handled or disposed of by anyone
except an authorized dealer.
Improper work on the SRS components or wiring could result in
inadvertent deployment of the airbags or could render the SRS
system inoperative. Either situation could result in serious
injury
WARNING: If the car has had any front-end damage, have the SRS system
inspected by an authorized dealer to ensure it is working
properly.
WARNING: If any of the following conditions occur, the SRS is not
working properly. Immediately have it inspected by an
authorized dealer:
* The SRS warning light does not illuminate when you start
the car.
* The SRS warning light does not go off after about 7 seconds.
* The SRS warning light illuminates while driving.

CAUTION: Disconnect negative battery cable before servicing any air
bag system, steering column or passenger side dash
component. After any repair, turn ignition key to the ON
position from passenger's side of vehicle in case of
accidental air bag inflation
AIR CONDITIONING SERVICING
WARNING: Avoid breathing R-134a refrigerant and PAG lubricant vapors,
exposure may irritate eyes, nose and throat. To remove
R-134a from system use R-134a recycling equipment that meets
SAE J2210 specifications. If accidental system discharge
occurs, ventilate work area before resuming service.
WARNING: R-134a service equipment or vehicle A/C systems SHOULD NOT
be pressure tested or leak tested with compressed air. Some
mixtures of air/R134a have shown to be combustible at
elevated pressures. These mixtures are dangerous and may
cause fire and/or explosions. See AIR CONDITIONING SERVICE
article in GENERAL INFORMATION section.
AIR CONDITIONING MAINTENANCE
WARNING: NEVER add A/C refrigerant to correct a non-cooling problem
unless pressure gauges are connected to the system by a
certified technician. Lack of cooling may be caused by a
restriction, therefore adding refrigerant can cause a
dangerous pressure rise.
ANTI-LOCK BRAKE SYSTEM
CAUTION: The anti-lock brake system contains electronic equipment that
can be susceptible to interference caused by improperly
installed or high output radio transmitting equipment. Since
this interference could cause the possible loss of the
antilock braking capability, such equipment should be
installed by qualified professionals.
On models equipped with anti-lock brake systems, ALWAYS
observe the following cautions:
* DO NOT attempt to bleed hydraulic system without first
referring to the appropriate ANTI-LOCK BRAKE SYSTEM article
in the BRAKES Section.
* DO NOT mix tire sizes. As long as tires remain close to the
original diameter, increasing the width is acceptable.
Rolling diameter must be identical for all 4 tires. Some
manufacturers recommend tires of the same brand, style and
type. Failure to follow this precaution may cause inaccurate
wheel speed readings.
* Use ONLY recommended brake fluids. DO NOT use silicone brake
fluids in an ABS-equipped vehicle.
AUTOMATIC TRANSAXLE FLUID SERVICE
WARNING: Make certain no fluid is spilled when the transaxle fluid
is inspected. Wipe up any spilled fluid completely.
AXLE FLUID
CAUTION: Axle lubricant should be changed whenever the axle has

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

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.

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

Fig. 20: Underhood Power Distribution Center
Courtesy of Chrysler Corp.
WARNING: Always disconnect battery ground cable before servicing
"high-current fuses. It is recommended that "high-current"
fuses be replaced by a qualified technician.
Power Distribution Center Relay & Fuse Identification
A - Starter Relay
B - Trailer Lights Relay
C - Auto Transmission Relay
D - Anti-Lock Brake System Relay
E - Auto Shutdown Relay
F - Air Conditioning Clutch Relay
G - Horn Relay
H - Fuel System Relay
J - ABS Warning Light Relay
K - Fog Lamp 2 Relay
L - Fog Lamp 1 Relay
1 - 30 Amp (Pink)
Engine Control
2 - 40 Amp (Green)
Ignition Run/Accessory
3 - 40 Amp (Green)
Ignition Run
4 - 50 Amp (Red)
Instrument Panel, Horn, Parking Lights
5 - 20 Amp (Blue)
Fuel Pump
6 - 30 Amp (Pink)
Trailer Lights
7 - 40 Amp (Green)
Stop/Headlight
8 - 40 Amp (Green)
ABS Pump
9 - 20 Amp (Yellow)
Hazard Lights
10 - 20 Amp (Yellow)
Horn/AC
11 - 15 Amp (Blue)

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

FUEL LINE BLEEDING
NOTE: Fuel line bleeding is necessary if fuel injection pump is
replaced, fuel filter/water separator is not filled with
diesel fuel before installing or vehicle ran out off fuel.
Bleed high-pressure fuel lines if connections are loosened or
replaced. If engine has not been operated for an extended
time, bleed fuel lines before next initial engine start-up.
WARNING: DO NOT bleed fuel lines on a hot engine, as high exhaust
temperatures may cause a fire. Carefully bleed fuel lines, as
fuel is under extremely high pressure and could penetrate
skin. Use safety goggles and protective clothing when
bleeding fuel lines.
1) Loosen banjo bolt holding low-pressure fuel supply line to
side of fuel injection pump. Wrap a towel around banjo fitting to
catch fuel. Crank engine quickly and release key before engine starts.
This will operate fuel transfer pump for about 25 seconds.
2) If fuel is not present at fuel supply line after 25
seconds, turn ignition off. Repeat engine crank procedure until fuel
is present at fuel supply line. Tighten banjo bolt at fuel supply line
to specification. See TORQUE SPECIFICATIONS.
CAUTION: Ensure parking brake is applied and transmission is in
Neutral before bleeding fuel injection pump or high-pressure
fuel lines. DO NOT operate starter for more than 30 seconds
when bleeding fuel injection pump or high-pressure fuel
lines. Allow 2-minute intervals between starter operations.
3) To bleed air from fuel injection pump, ensure parking
brake is applied and transmission is in Neutral, as engine may start
when operating starter to bleed air from fuel injection pump. Operate
starter for 30 seconds to bleed any trapped air in fuel injection
pump.
4) To bleed high-pressure fuel lines, ensure parking brake is
applied and transmission is in Neutral, as engine may start when
operating starter to bleed high-pressure fuel lines. Loosen high-
pressure fuel line nut at fuel injector.
5) Operate starter until steady fuel flow exists at high-
pressure fuel line. Tighten high-pressure fuel line nut to
specification. See TORQUE SPECIFICATIONS. Start engine. Repeat
procedure on each high-pressure fuel line until engine operates
smoothly.
FUEL FILTER/WATER SEPARATOR & WATER-IN-FUEL SENSOR
NOTE: Vehicle also contains an in-tank fuel filter located on
bottom of fuel tank module. For servicing procedure, see FUEL
TANK MODULE & IN-TANK FUEL FILTER under FUEL SYSTEM.
NOTE: When fuel filter/water separator is being replaced,
manufacturer recommends cleaning the pre-filter. See FUEL
HEATER under FUEL SYSTEM for servicing of pre-filter.
Removal
1) Ensure engine is off. Place drain pan below drain tube at
fuel filter/water separator. See Fig. 3. Rotate handle on drain valve
forward, toward front of vehicle to DRAIN position. Drain valve is
located near top of fuel filter/water separator. See Fig. 3. Once fuel
is drained from fuel filter/water separator, rotate handle on drain
valve back to CLOSE position.