ABS DODGE RAM 1999 Service Manual PDF

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)

2) Apply voltage to Light Blue/Yellow wire at heated mirror
and ground Black wire at heated mirror. Mirror should become warm to
touch. If mirror is not warm to touch, remove mirror and test wires
for continuity. If no continuity exists, repair wires. If wires are
okay, replace mirror. To test defogger switch, see appropriate wiring
diagram in REAR WINDOW DEFOGGERS article.
NOTE: On Ram Pickup, heated mirror is controlled by mirror defogger
switch.
Ram Pickup
1) Turn ignition on. While watching instrument panel
voltmeter, turn heated mirror switch on. Voltmeter needle should
deflect. With heated mirror on, mirror should be warm to touch after
3-4 minutes. If system operates as described, system is okay at this
time.
2) If system does not operate as described, go to next step.
Illuminated indicator light means only that voltage exists at heated
mirror relay.
3) Ensure ignition is on. Check fuses in Power Distribution
Center (PDC) and junction block. Ensure fuses are fully seated and
connections are secure. If mirrors are still inoperative, problem is
in heated mirror control, mirror heating grid and/or heated mirror
harness or connectors. If turning switch on causes a large deflection
in instrument panel voltmeter, check for a short circuit in system.
Repair as necessary.
REMOVAL & INSTALLATION
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.
HEATED MIRROR SWITCH
Removal & Installation (Ram Pickup)
Heated mirror switch is part of HVAC control unit. See
appropriate AUTOMATIC A/C-HEATER SYSTEMS article in appropriate AIR
CONDITIONING & HEATING SERVICE & REPAIR section.
POWER MIRROR SWITCH
Removal & Installation (Caravan, Town & Country, & Voyager)
1) Remove cover from over steering column. Remove screws
holding instrument cluster bezel to dash (above cluster lens). Remove
screws holding instrument cluster bezel to dash from each side of
steering column. Disconnect clip holding instrument cluster bezel to
dash from above right vent louver.
2) Separate instrument cluster bezel from dash. Disconnect
wires from back of bezel. Disengage lock tabs above and below mirror
switch. Pull mirror switch from headlight switch bezel. To install,
reverse removal procedure.
Removal & Installation (Dakota & Durango)
1) Pull power mirror switch control knob rearward to remove
it from switch body. Remove nut securing switch to door trim panel.
Pull door latch handle to open position and remove screw securing trim
panel to door. Remove manual window crank handle, if equipped. Release
locking tab on power window/lock switch, if equipped. Remove power
window/lock switch and unplug connector.

2) Remove remaining screws from door trim panel. Using a trim
stick, pry perimeter of trim panel away from door sufficiently to
unplug power mirror switch connector. Remove power mirror switch. To
install, reverse removal procedure.
Removal & Installation (Ram Pickup)
1) Remove door pull cup from door trim panel. Reach through
door pull cup opening to release locking tab on power window/lock
switch. Remove power window/lock switch and unplug connector.
2) Using a trim stick, pry perimeter of trim panel away from
door. Remove door trim panel. Unplug power mirror switch connector.
Remove power mirror switch. To install, reverse removal procedure.
Removal & Installation (Ram Van & Ram Wagon)
Disconnect battery. Remove knee blocker and lower instrument
panel cover. Remove mirror control knob by pulling straight out.
Remove inside hood release handle screws and lower handle. Reach under
instrument panel and disconnect switch connector. Remove 2 switch
mounting plate screws and pull switch from panel. Remove switch-to-
mounting plate nut and remove switch. To install, reverse removal
procedure.
POWER MIRROR ASSEMBLY
Removal & Installation (Caravan, Town & Country, & Voyager)
Remove screw and power mirror front cover. Remove 3 mirror
attaching screws and pull mirror away from door. Disconnect mirror
electrical connectors. To install, reverse removal procedure.
Removal & Installation (Dakota & Durango)
1) Unscrew door lock knob. Remove power window/lock switch
assembly by inserting a screwdriver in notch at forward end of switch
housing to release locking tabs. Pull switch assembly forward and out
from door panel. Remove trim plug from top of trim panel. Remove screw
under trim plug.
2) Remove 2 screws from bottom of door trim panel. Remove arm
rest screw. Using a trim stick, pry trim panel away from door. Roll
door watershield away from lower rear corner of door to expose panel
access. Reach inside door and disconnect mirror wiring connector.
3) Remove 3 mirror nuts and pull mirror loose from door. Feed
wiring harness out through hole in outer door panel. To install,
reverse removal procedure.
Removal & Installation (Ram Pickup, Ram Van & Ram Wagon)
1) Raise window to full up position. Remove remote door latch
control handle. Remove power window/lock switch by inserting thin-
blade screwdriver into switch housing forward notch and depressing
locking tab. Pull switch bezel out and forward to remove from door
panel.
2) Remove 2 screws from bottom (front and rear) of trim
panel. Using trim stick, pry trim panel away from door. Roll door
watershield away from lower rear corner of door to expose panel
access. Reach inside door and disconnect mirror wiring connector.
NOTE: Spray silicone on mounting bracket cover grommet to prevent
grommet from coming off when cover is moved up on mirror
stem.
3) Remove mirror mounting bracket cover and slide up on
mirror stem. Remove mirror mounting bracket nuts. Pull mirror loose
from door and feed wiring harness out through hole in outer door
panel. To install, reverse removal procedure.

Removal (A/T Models)
Raise and support vehicle. Disconnect electrical connector
from park/neutral switch. Park/neutral switch is located on side of
transmission case, near shift linkage. Unscrew park/neutral switch
from transmission case. Remove seal ring from park/neutral switch.
Installation
1) Apply parking brake. Place shift lever in Park and
Neutral. Ensure park/neutral switch operating levers in transmission
are centered in the park/neutral switch opening on transmission case.
2) Using NEW seal ring, install park/neutral switch. Tighten
park/neutral switch to specification. See TORQUE SPECIFICATIONS.
Install electrical connector. Add ATF as necessary.
ACCELERATOR PEDAL POSITION SENSOR (APPS)
NOTE: APPS is replaced as assembly, including lever, brackets, and
sensor.
Removal
1) Disconnect negative battery cables. Remove cable cover.
Using finger pressure only, disconnect end of speed control servo
cable from throttle lever pin by pulling forward on connector while
holding lever rearward. Using 2 small screwdrivers, pry throttle cable
connector socket from throttle lever ball.
2) Disconnect transmission kickdown cable (if equipped).
Compress pinch tabs on cruise control and throttle cables. Pull cables
rearward to remove from cable mounting brackets. See Fig. 4.
Disconnect electrical connector and retaining bolts. Remove APPS
sensor.
Installation
To install, reverse removal procedure. To calibrate ECM, turn
ignition on. Without starting engine, slowly press throttle pedal to
floor and then slowly release.
Fig. 4: Locating Throttle Position (TP) Sensor
Courtesy of Chrysler Corp.
RELAYS & SOLENOIDS

fitting and fuel lines are clean. Note location of release tab and
pull tab on disconnect fitting. See Fig. 6.
CAUTION: Release tab must be pressed downward before removing pull tab
or pull tab will be damaged.
2) Press release tab downward. Use screwdriver to pry pull
tab upward until pull tab separates from disconnect fitting. Remove
disconnect fitting from fuel line. Inspect components for damage. If
disconnect fitting is damaged, entire assembly must be replaced, as
only pull tab can be replaced.
3) To install, ensure fuel line and disconnect fitting are
clean. Lubricate fuel line and disconnect fitting with engine oil.
Install disconnect fitting on fuel line until disconnect fitting
bottoms on fuel line.
4) Install NEW pull tab until pull tab locks in disconnect
fitting. DO NOT reuse old pull tab. Pull on fuel line and disconnect
fitting to ensure components are properly locked together. Reconnect
negative battery cables. Start engine and check for leaks.
Removal & Installation (Dual Tab)
1) Disconnect negative battery cables. Ensure disconnect
fitting and fuel lines are clean. Note location of tabs on disconnect
fitting. See Fig. 6.
2) Squeeze both tabs against disconnect fitting. Pull
disconnect fitting from fuel line. The plastic retainer will remain on
the fuel system component being serviced. The "O" rings and spacer
will remain in the disconnect fitting.
3) Inspect components for damage. If disconnect fitting is
damaged, entire assembly must be replaced. The only component that may
be replaced is the plastic retainer. If plastic retainer must be
removed from fuel system component, carefully release the plastic
retainer from the fuel system component using 2 screwdrivers. Inspect
plastic retainer for cracks or damage. Replace plastic retainer if
defective.
4) To install, ensure fuel line and disconnect fitting are
clean. Lubricate fuel line and disconnect fitting with engine oil.
Install disconnect fitting on fuel line until click sound is heard.
5) Pull on fuel line and disconnect fitting to ensure
components are properly locked together. Reconnect negative battery
cables. Start engine and check for leaks.
Removal & Installation (Plastic Retainer Ring)
1) Disconnect negative battery cables. Ensure disconnect
fitting and fuel lines are clean. Note location of plastic retainer
ring on disconnect fitting. See Fig. 6.
NOTE: Plastic retainer ring must be pressed evenly into disconnect
fitting. If plastic retainer is not even, it will be
difficult to remove disconnect fitting from fuel line.
2) Firmly push disconnect fitting toward the fuel line while
pushing plastic retainer ring evenly into disconnect fitting. With
plastic retainer ring fully depressed, pull disconnect fitting from
fuel line.
3) Inspect components for damage. If disconnect fitting is
damaged, entire assembly must be replaced.
4) To install, ensure fuel line and disconnect fitting are
clean. Lubricate fuel line and disconnect fitting with engine oil.
Install disconnect fitting on fuel line until click sound is heard.
5) Pull on fuel line and disconnect fitting to ensure
components are properly locked together. Reconnect negative battery
cables. Start engine and check for leaks.

2) Disconnect drain tube from drain valve. Disconnect
electrical connector for Water-In-Fuel (WIF) sensor at bottom of fuel
filter/water separator. See Fig. 3.
3) Support canister for fuel filter/water separator and
remove canister nut from top of filter mounting head. See Fig. 3.
Remove canister with fuel filter/water separator and seal ring from
filter mounting head. Remove fuel filter/water separator from
canister.
4) Remove "O" ring from top of shaft inside the canister.
Remove bolts and drain valve from canister (if necessary).
5) Check the 2 probes inside the canister on end of WIF
sensor for contamination. Clean probes if contaminated. If
contamination cannot be removed from the probes, replace WIF sensor.
If replacing WIF sensor, remove WIF sensor and "O" ring from canister.
6) Fuel heater is located inside fuel filter housing. Heater
mounting plate, heating element, temperature sensor, and wiring
harness are serviced as an assembly. Disconnect heater electrical
connector from engine wiring harness near upper rear part of filter.
7) Disconnect electrical connector at end of 2-wire harness
before attempting to pass harness through filter header. Remove clip
retaining wires to connector. Remove wires from connector. Remove 3
fuel heater screws. Press on heater sealing grommet to remove heater
from filter canister header. Pass wire through hole in filter header.
Remove fuel heater.
Installation
1) Ensure inside of canister is clean. Using NEW "O" ring,
install WIF sensor on canister (if removed). Tighten WIF sensor to
specification. See TORQUE SPECIFICATIONS.
2) Install drain valve on canister (if removed). Tighten
drain valve-to-canister bolts to specification. See TORQUE
SPECIFICATIONS.
3) Install NEW "O" ring on shaft inside canister. Coat "O"
ring with diesel fuel. Install NEW fuel filter/water separator and NEW
seal ring in canister. Coat seal ring with diesel fuel.
NOTE: Canister for fuel filter/water separator should be filled
with diesel fuel before installing. If canister cannot be
filled with diesel fuel, low-pressure fuel lines must be bled
after installation.
CAUTION: When installing canister on filter mounting head, ensure tab
areas on outside of canister align with tabs on filter
mounting head. This must be done to prevent damage to
canister and filter mounting head.
4) Fill canister for fuel filter/water separator with diesel
fuel. Install canister with fuel filter/water separator on filter
mounting head. Ensure canister fully engages with filter mounting head
and tab areas on outside of canister align with tabs on filter
mounting head.
5) Install and tighten canister nut to specification. See
TORQUE SPECIFICATIONS.
6) To install remaining components, reverse removal
procedure. If canister was not filled with diesel fuel, bleed low-
pressure fuel lines before starting engine. See FUEL LINE BLEEDING
under FUEL SYSTEM. Start engine and check for fuel leaks.
FUEL TANK MODULE & IN-TANK FUEL FILTER
NOTE: In-tank fuel filter is located on bottom of fuel tank module
which also contains the fuel gauge sending unit. Fuel tank
module is mounted on top of fuel tank.


N - R EM OVE/IN STA LL/O VER HAU L - R W D - G ASO LIN E

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Removal, Overhaul & Installation - Gasoline
Dakota, Durango, Ram Pickup, Ram Van, Ram Wagon
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 basically an
unbolt and bolt-on procedure, only a torque specification may be
provided.
COMPUTERIZED ENGINE CONTROLS
POWERTRAIN CONTROL MODULE (PCM)
NOTE: If replacing Powertrain Control Module (PCM), the correct
vehicle mileage and Vehicle Identification Number (VIN) must
be programmed into the PCM to prevent Diagnostic Trouble
Codes (DTCs) from being set in the Anti-Lock Brake System
(ABS) module and Supplemental Restraint System (SRS) module\
.
To program PCM and clear DTCs from ABS and SRS modules, see
PCM PROGRAMMING. If replacing Powertrain Control Module (PCM)\
on models equipped with a Smart Key Immobilizer Module
(SKIM), the secret key data must also be updated to enable
engine starting. To update secret key data, see PCM
PROGRAMMING.
Removal & Installation
1) PCM is located in the engine compartment. See Figs. 1-3.
Disconnect negative battery cable. Remove cover for access to
electrical connectors at PCM. Disconnect electrical connectors from
PCM. Remove PCM retaining bolts and PCM.
2) To install, reverse removal procedure. Tighten PCM
retaining bolts to specification. See TORQUE SPECIFICATIONS.
Fig. 1: Locating PCM (Dakota & Durango)
Courtesy of Chrysler Corp.

Procedure For Programming PCM & Clearing DTCs From ABS & SRS
Modules
Connect scan tool to Data Link Connector (DLC). DLC is
located under left side of instrument panel. Using scan tool, enter
correct VIN and mileage into PCM. Using scan tool manufacturer's
instructions, clear DTCs from ABS and SRS modules.
Procedure For Updating Secret Key Data
1) Connect scan tool to Data Link Connector (DLC). DLC is
located under left side of instrument panel.
2) Go to ENGINE and then MISC menus on scan tool. Place the
SKIM in SECURED ACCESS MODE by using the appropriate Personal
Identification Number (PIN) for this vehicle. PIN may be obtained from\
the owner, vehicle's invoice, or from the manufacturer. Select UPDATE
THE SECRET KEY DATA. The data will be transferred from Smart Key
Immobilizer Module (SKIM) to the PCM, allowing the vehicle to start.
NOTE: On Ram Van and Ram Wagon, if 3 attempts are made to enter the
SECURED ACCESS MODE using the incorrect Personal
Identification Number (PIN), the SECURED ACCESS MODE will be
locked out for one hour. To exit this locked out mode, leave
ignition switch in the ON position for one hour with all
accessories turned off. It may be necessary to monitor
battery state and connect a battery charger if necessary.
ENGINE SENSORS & SWITCHES
BATTERY TEMPERATURE SENSOR
Removal & Installation
Battery temperature sensor is snapped into center of battery
tray, directly below the battery. Remove battery. Disconnect
electrical connector for battery temperature sensor. Pry battery
temperature sensor straight upward from battery tray. To install,
reverse removal procedure.
BRAKE SWITCH
NOTE: Brake switch may also be referred to as brakelight switch or
stoplight switch.
Removal (Dakota, Durango & Ram Pickup)
1) Brake switch is located near top of brake pedal. Remove
lower instrument panel cover for access to brake switch if necessary.
Disconnect electrical connector from brake switch. Depress and hold
brake pedal downward.
2) Rotate brake switch counterclockwise approximately 30
degrees so alignment tab on brake switch aligns with opening on
mounting bracket. Pull brake switch rearward from mounting bracket.
NOTE: Before installing brake switch, plunger on brake switch must
be pulled outward to fully extended position and then pushed
inward 4 detent positions to ensure proper brake switch
adjustment.
Installation
1) Pull plunger on brake switch outward to the fully extended
position. Push plunger on brake switch inward 4 detent positions. The
brake switch will click at each detent position when pushing plunger
inward.
2) Install electrical connector on brake switch. Depress
brake pedal as far as possible. Install brake switch in mounting

Fig. 5: Locating Intake Air Temperature (IAT) Sensor (Dakota 3.
9L, 5.2L & 5.9L, Durango, Ram Pickup 3.9L, 5.2L, & 5.9L, Ram Van & Ram
Wagon)
Courtesy of Chrysler Corp.
Fig. 6: Locating Intake Air Temperature (IAT) Sensor (Ram Pickup
8.0L)
Courtesy of Chrysler Corp.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

Removal & Installation (Dakota, Durango & Ram Pickup 2.5L,
3.9L, 5.2L & 5.9L)
1) MAP sensor is located near throttle body and contains a 3-
pin electrical connector with an L-shaped rubber hose connecting it to
the throttle body. See Fig. 7 or 8. Remove air inlet duct or air
cleaner assembly for access to MAP sensor if necessary.
2) Ensure area around MAP sensor is clean. Disconnect
electrical connector at MAP sensor. Remove MAP sensor retaining bolts.
Remove MAP sensor while disconnecting L-shaped rubber hose from
throttle body. Remove L-shaped rubber hose from MAP sensor.
3) To install, reverse removal procedure. Ensure L-shaped
rubber hose is properly installed on throttle body and MAP sensor.
Tighten MAP sensor retaining bolts to specification. See TORQUE
SPECIFICATIONS.
Removal & Installation (Ram Pickup 8.0L)
1) MAP sensor is located on upper side of intake manifold and
contains a 3-pin electrical connector. See Fig. 9. Disconnect
electrical connector at MAP sensor.
2) Ensure area around MAP sensor is clean. Remove MAP sensor
retaining bolts. Remove MAP sensor with rubber seal gasket from intake
manifold. Rubber seal gasket is part of the MAP sensor and is not
serviceable. Inspect rubber seal gasket for damage. Replace MAP sensor
with rubber seal gasket if gasket is defective.
3) To install, reverse removal procedure. Ensure seal area in
upper intake manifold is clean before installing MAP sensor. Lubricate
rubber seal gasket with engine oil before installing MAP sensor.
Tighten MAP sensor retaining bolts to specification. See TORQUE
SPECIFICATIONS.
Removal & Installation (Ram Van & Ram Wagon)
1) MAP sensor is located near throttle body and contains a 3-
pin electrical connector with an L-shaped rubber hose connecting it to
the throttle body. See Fig. 8. Remove engine cover and air cleaner
assembly for access to MAP sensor if necessary.
2) Ensure area around MAP sensor is clean. Disconnect
electrical connector at MAP sensor. Remove MAP sensor retaining bolts.
Remove MAP sensor while disconnecting L-shaped rubber hose from
throttle body. Remove L-shaped rubber hose from MAP sensor.
3) To install, reverse removal procedure. Ensure L-shaped
rubber hose is properly installed on throttle body and MAP sensor.
Tighten MAP sensor retaining bolts to specification. See TORQUE
SPECIFICATIONS.
Fig. 7: Locating Manifold Absolute Pressure (MAP) Sensor (Dakota
2.5L)
Courtesy of Chrysler Corp.