DODGE RAM 1999 Service Repair Manual

Removal
Disconnect negative battery cable. Remove drive belts from
crankshaft pulley. Remove fan and shroud. Remove crankshaft pulley and
vibration damper. Pry oil seal from front cover.
Installation
1) Use Seal Installer (6635) for seal installation. Installe\
r
should fit with minimum interference. If installer does not fit, front
cover must be removed and installed properly.
2) Position small diameter of oil seal over seal installer.
Using vibration damper bolt, tighten seal installer to draw seal into
position. Remove vibration damper bolt and seal installer. To complete
installation, reverse removal procedure.
FRONT COVER
Removal
1) Disconnect battery. Drain coolant. Remove power steering
pump (if equipped). Remove water pump. See WATER PUMP.
2) Remove crankshaft pulley and vibration damper. Loosen oil
pan bolts. Remove oil pan-to-front cover bolts on each side of oil
pan. Remove bolts, front cover and gasket. DO not damage oil pan
gasket.
Installation
1) Ensure sealing surfaces are clean. Apply a 1/8" (3.17 mm)\
bead of RTV sealant to oil pan gasket. Install gasket, front cover and
bolts. DO NOT tighten bolts at this time.
2) Install front cover oil seal. See FRONT COVER OIL SEAL.
Tighten front cover, oil pan and then vibration damper bolts to
specification. See TORQUE SPECIFICATIONS table. To complete
installation, reverse removal procedure.
TIMING CHAIN
Inspection
1) Remove front cover. See FRONT COVER. Position ruler at
camshaft sprocket, near timing chain link, to check timing chain
stretch.
NOTE: When applying torque to camshaft sprocket bolt, DO NOT allow
crankshaft to move. It may be necessary to hold crankshaft.
2) Place torque wrench on camshaft sprocket bolt. Apply 30
ft. lbs. (41 N.m) torque with cylinder heads installed, or 15 ft. lbs.\
(20 N.m) with cylinder heads removed, on camshaft sprocket bolt in
direction of engine rotation. Note reading on ruler.
3) Apply same amount of torque in opposite direction and note
amount of timing chain movement on ruler. If movement exceeds 1/8" (3.
17 mm), replace timing chain.
Removal
Rotate crankshaft so timing marks are aligned. See Fig. 8.
Remove camshaft sprocket bolt, camshaft sprocket, timing chain and
crankshaft sprocket.
Installation
1) Install timing chain and sprockets. Ensure timing marks
are aligned. See Fig. 8. Install camshaft sprocket bolt and tighten to
specification. See TORQUE SPECIFICATIONS table.
2) Ensure camshaft end play is within specification. See
CAMSHAFT table under ENGINE SPECIFICATIONS. If end play is not within
specification, replace thrust plate located between camshaft sprocket

and camshaft. To install remaining components, reverse removal
procedure.
Fig. 8: Aligning Timing Marks
Courtesy of Chrysler Corp.
ROCKER ARMS
Removal
Disconnect spark plug wires, PCV and fuel evaporation hoses.
Remove valve covers. Remove bolts, pivots, and rocker arms. Wire
components together for installation reference. Mark each push rod for
location, and remove (if necessary).
CAUTION: To avoid piston-to-valve contact during rocker arm
installation, crankshaft must be placed in specified
position. Wait 5 minutes before starting engine to allow
valve lifters to bleed down after rocker arm installation.
Installation
1) On 3.9L engine, locate "V6" mark stamped on vibration
damper (147 degrees ATDC). Rotate engine by hand until "V6" mark lines\
up with TDC mark on timing chain cover.
2) On 5.2L and 5.9L engines, locate "V8" mark stamped on
vibration damper (147 degrees ATDC). Rotate engine by hand until "V8"
mark lines up with TDC mark on timing chain cover.
3) Install rocker arm and pivot assemblies and tighten bolt
to 21 ft. lbs. (28 N.m). Wait 5 minutes before starting engine to
allow valve lifters to bleed down after rocker arm installation. To
install remaining components, reverse removal procedure. Tighten valve
cover bolts to 95 INCH lbs. (11 N.m).
VALVE LIFTERS

Removal
Remove air cleaner. Remove rocker arms. See ROCKER ARMS.
Remove intake manifold. See INTAKE MANIFOLD. Remove yoke retainer and
aligning yoke. Use Valve Lifter Remover/Installer (C-4129-A) to remove\
valve lifter(s).
NOTE: Cylinder block must be marked to indicate oversize valve
lifters. See SPECIAL ENGINE MARKS under ENGINE
IDENTIFICATION.
Inspection
Inspect components for damage. Measure lifter O.D. and bore
diameter in cylinder block. Determine oil clearance. Clearance must be
within specification. See VALVE LIFTERS table under ENGINE
SPECIFICATIONS. Cylinder block can be bored for oversize lifters.
CAUTION: DO NOT allow engine RPM to exceed fast idle until valve
lifters have filled with oil and become quiet.
Installation
1) Lubricate valve lifters and push rods before installing in
original locations. Ensure valve lifter is installed so oil feed hole
in side of valve lifter is facing upward, away from crankshaft.
2) Align yokes with arrow pointing toward camshaft. Install
yoke retainer, and tighten bolts to specification. See TORQUE
SPECIFICATIONS table.
CAMSHAFT
Removal
1) Remove engine. See ENGINE. Remove front cover and timing
chain. See FRONT COVER and TIMING CHAIN.
2) Remove valve lifters. See VALVE LIFTERS. Remove
distributor and distributor drive shaft. Remove camshaft thrust plate,
noting location of oil tab for installation reference. See Fig. 9.
Remove camshaft.
Fig. 9: Positioning Oil Tab
Courtesy of Chrysler Corp.
Inspection
Inspect camshaft and camshaft bearings for wear. Measure

camshaft journal diameter and camshaft bearing I.D. Replace camshaft
or camshaft bearings if not within specification. See CAMSHAFT table
under ENGINE SPECIFICATIONS.
CAUTION: If camshaft is replaced, valve lifters must also be replaced.
Whenever new camshaft or valve lifters are installed,
manufacturer recommends addition of one pint of Chrysler
crankcase conditioner to engine oil for at least 500 miles to
aid break-in.
Installation
1) Ensure cup plugs are installed in oil passages behind
thrust plate. Lubricate camshaft and bearings, and install within 2"
(50.8 mm) of final installation location.
2) Install Camshaft Installer (C-3509), with long area behin\
d
distributor drive gear. See Fig. 10. This prevents camshaft from
contacting plug located in rear of cylinder block. Install distributor
lock bolt to retain camshaft installer.
3) Install camshaft thrust plate and oil tab. Ensure tang
engages with lower right hole of camshaft thrust plate. Tighten
camshaft thrust plate bolts to specification. See TORQUE
SPECIFICATIONS table. Top edge of oil tab should be flat against
camshaft thrust plate for timing chain lubrication. See Fig. 9.
4) To install remaining components, reverse removal
procedure. Check camshaft end play. If end play exceeds specification,
replace thrust plate. See CAMSHAFT table under ENGINE SPECIFICATIONS.
Ensure components are installed in original location.
CAUTION: DO NOT allow engine RPM to exceed fast idle until valve
lifters have filled with oil and become quiet.
Fig. 10: Installing Camshaft
Courtesy of Chrysler Corp.
CAMSHAFT BEARINGS

Removal & Installation
1) Use Camshaft Bearing Remover/Installer (C-3132-A) for
camshaft bearing replacement. Replace camshaft bearing if damaged or
if I.D. is not within specification. See CAMSHAFT table under ENGINE
SPECIFICATIONS.
2) Ensure oil holes are aligned. Ensure oil hole in No. 2
bearing aligns with oil hole to left cylinder head, and oil hole in
No. 3 bearing (3.9L) or No. 4 bearing (5.2L and 5.9L) aligns with oi\
l
hole to right cylinder head. Install NEW camshaft plug at rear of
cylinder block.
DISTRIBUTOR DRIVE SHAFT BUSHING
Removal
1) Rotate crankshaft so No. 1 cylinder is at TDC on
compression stroke. Remove distributor and distributor drive shaft.
Insert Bushing Puller (C-3052) into bushing, and thread down until
tight.
2) Hold bushing puller bolt, and rotate bushing puller nut
until distributor drive shaft bushing is removed.
Installation
1) Install NEW distributor drive shaft bushing over
burnishing end of Bushing Installer (C-3053). Insert bushing installer\
and distributor drive shaft bushing into cylinder block.
CAUTION: DO NOT ream distributor drive shaft bushing.
2) Using hammer, drive bushing installer and distributor
drive shaft bushing into cylinder block. Tighten nut to pull bushing
installer through distributor drive shaft bushing. Tightening nut
expands bushing tight in cylinder block and burnishes it to correct
size.
3) Ensure No. 1 cylinder is at TDC on compression stroke.
Install distributor drive shaft so slot is aligned toward left front
intake manifold bolt as viewed from rear of engine. Install
distributor with rotor positioned to No. 1 cylinder in distributor
cap.
REAR CRANKSHAFT OIL SEAL
Removal & Installation (Crankshaft Installed)
1) Remove oil pan. See OIL PAN. Remove oil pump. Remove rear
main bearing cap and discard lower rear crankshaft oil seal. Carefully
remove upper rear crankshaft oil seal and discard seal.
2) Lubricate new oil seal. Rotate upper rear crankshaft oil
seal in cylinder block with Yellow paint toward rear of engine.
Install lower rear crankshaft oil seal in main bearing cap with Yellow
paint toward rear of engine.
3) To prevent oil leakage, apply one drop of Loctite 515
sealant next to oil seal on main bearing cap surface before
installing. Apply silicone adhesive sealant at bearing cap-to-cylinder
block joint. See Fig. 11. Install main bearing cap, and tighten bolts
to specification. See TORQUE SPECIFICATIONS table. To install
remaining components, reverse removal procedure.
Removal & Installation (Crankshaft Removed)
1) Remove rear crankshaft oil seals from cylinder block and
main bearing cap. Lubricate oil seal. Install rear crankshaft oil
seals with Yellow paint toward rear of engine.
2) To prevent oil leakage, apply one drop of Loctite 515
sealant next to oil seal on main bearing cap surface before
installing. Apply silicone adhesive sealant at bearing cap-to-cylinder

block joint. See Fig. 11.
Fig. 11: Installing Rear Crankshaft Oil Seal
Courtesy of Chrysler Corp.
WATER PUMP

CAUTION: After removing fan clutch assembly, DO NOT store fan clutch
with rear of shaft pointing downward. Silicone fluid from fan
clutch may drain into fan drive bearing, causing lubricant
failure.
Removal
1) Disconnect negative battery cable. Drain cooling system.
Remove throttle cable at top of fan shroud. Unsnap coolant overflow
tank from fan shroud and lay aside. DO NOT disconnect coolant hose.
2) Remove upper radiator hose. Using Fan Wrench (SP346) from\
Set (2017DSP), remove fan clutch assembly from water pump by turning
nut counterclockwise as viewed from front. DO NOT remove fan clutch
assembly at this time.
3) Remove fan shroud bolts and clips. Remove fan shroud and
fan clutch assembly as a unit. Locate accessory drive belt tensioner,
and rotate tensioner clockwise (counterclockwise on heavy-duty cycle
engines) to release tension on accessory drive belt.
4) Note drive belt routing for installation reference. Belt
must be correctly routed during installation, or engine will overheat
due to water pump rotating in wrong direction.
5) Remove bolts and water pump pulley. Disconnect lower
radiator hose and heater hoses. Remove coolant return tube from water
pump. Remove bolts, water pump and gasket.
Installation
To install, reverse removal procedure using NEW gasket.
Tighten bolts to specification. See TORQUE SPECIFICATIONS table. Fill
system with coolant. Ensure accessory drive belt is installed in
original direction to ensure proper rotation of water pump. See
Fig. 12 .
Fig. 12: Drive Belt Routing (Except 5.9L - Heavy Duty Cycle)
Courtesy of Chrysler Corp.

Fig. 13: Drive Belt Routing (5.9L - Heavy Duty Cycle)
Courtesy of Chrysler Corp.
OIL PAN
Removal (Dakota 2WD & Durango 2WD)
1) Disconnect negative battery cable. Remove oil dipstick and
distributor cap. Raise and support vehicle. Drain engine oil.
2) Remove exhaust pipe. Remove side engine mount bolts.
Slightly raise engine. When engine is at adequate height, install
bolts in side engine mount-to-frame bracket holes to support engine.
3) Lower engine, and allow it to rest on bolts installed in
side engine mounts. Remove oil pan bolts, oil pan and gaskets.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
where oil pan side gaskets meet end seals, and where end seals contact
cylinder block. See Fig. 14.
2) To facilitate oil pan installation, fabricate 4 alignment
dowels from 1 1/2" x 5/16" bolts. See Fig. 15. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table. To install remaining

components, reverse removal procedure.
Removal (Dakota 4WD & Durango 4WD)
1) Disconnect negative battery cable. Remove oil dipstick.
Drain engine oil. Remove exhaust pipe crossover and lower transmission
cover.
2) Remove front drive axle for access to oil pan. For front
drive axle removal, loosen wheel lug nuts. Remove cotter pin, lock nut
and spring washer. Loosen axle shaft nut with vehicle on floor and
brakes applied. Raise and support vehicle.
CAUTION: DO NOT pull on rubber boot during axle shaft removal. Pull on
outer CV joint only.
3) Remove wheels and skid plate. Remove axle shaft nut.
Remove axle shaft-to-differential flange bolts at front drive axle.
Support axle shaft, and separate axle splines from wheel hub by
pulling inward at outer CV joint.
4) Remove remaining axle shaft. Mark front drive shaft and
transfer case yoke for installation reference. Remove front drive
shaft from transfer case. Disconnect vacuum hoses from shift motor and
electrical connections at shift indicator switch.
5) Support front drive axle using a floor jack. Remove front
drive axle and shift motor bolts. Lower floor jack, and remove front
drive axle with drive shaft. Remove transmission lower cover. Remove
bolts, oil pan and gasket.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
oil pan side gaskets meet end seals and end seals contact cylinder
block. See Fig. 14.
2) To facilitate oil pan installation, fabricate 4 alignment
dowels from 1 1/2" x 5/16" bolts. See Fig. 15. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table.
3) To install remaining components, reverse removal
procedure. When installing front drive axle, loosely install all bolts
before tightening to specification. Tighten axle shaft nut to
specification with vehicle on ground. See TORQUE SPECIFICATIONS table.
Ensure reference marks on transfer case yoke and front drive shaft are
aligned.
Removal (Ram Pickup & Ram Van/Wagon - 3.9L)
1) Disconnect negative battery cable. Remove oil dipstick. On
Ram Van/Wagon, remove engine cover. On all models, remove air cleaner
and engine controller. Raise and support vehicle. Drain engine oil.
2) Remove left engine-to-transmission strut. Loosen exhaust
pipe support bracket. Disconnect exhaust pipe. On Ram Pickup, remove
oil pan and gasket.
3) On Ram Van/Wagon, remove starter, transmission dust
shield, oxygen sensor and air injection tube. On all models, remove
right engine mount nut. Loosen, but DO NOT remove, left engine mount
nut.
4) Support right side of engine using jackstand. Remove
transmission mount through-bolt, and support transmission using
jackstand. Raise engine and transmission enough for oil pan removal.
Remove bolts, oil pan and gasket.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
oil pan side gaskets meet end seals and end seals contact cylinder
block. See Fig. 14.

2) To facilitate oil pan installation, fabricate 4 alignment
dowels from 1 1/2" x 5/16" bolts. See Fig. 15. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table. To install remaining
components, reverse removal procedure. Tighten bolts to specification.
See TORQUE SPECIFICATIONS table. To install remaining components,
reverse removal procedure.
Removal (Ram Pickup & Ram Van/Wagon - 5.2L & 5.9L)
Disconnect negative battery cable. Remove oil dipstick. Raise
and support vehicle. Drain engine oil. Remove exhaust pipe. Remove
left engine-to-transmission strut. Remove bolts, oil pan and gasket.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
oil pan side gaskets meet end seals and end seals contact cylinder
block. See Fig. 14.
2) To facilitate oil pan installation, fabricate 4 alignment
dowels from 1 1/2" x 5/16" bolts. See Fig. 15. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table. To install remaining
components, reverse removal procedure.
Removal (Grand Cherokee)
Disconnect negative battery cable. Remove oil dipstick. Raise
and support vehicle. Drain engine oil. Disconnect O2 sensor. Remove
exhaust pipe and starter. Remove left engine-to-transmission strut.
Disconnect oil level sensor (if equipped). Remove bolts, oil pan and
gasket. DO NOT damage oil level sensor.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
oil pan side gaskets meet end seals and end seals contact cylinder
block. See Fig. 14.
2) To facilitate oil pan installation on all models,
fabricate 4 alignment dowels from 1 1/2" x 5/16" bolts. See Fig. 15.
Tighten bolts to specification. See TORQUE SPECIFICATIONS table. To
install remaining components, reverse removal procedure.
Fig. 14: Applying Sealant On Oil Pan Sealing Surfaces
Courtesy of Chrysler Corp.