cooling DODGE RAM 1999 Service Manual PDF

(1) - Approximate quantity listed.
( 2) - Use an API energy conserving engine oil that is certified for
gasoline engines.
( 3) - Add this amount of fluid. Start engine and shift transmission
through all gears and back to Neutral. Add additional fluid to
bring fluid level to the MIN mark on dipstick. Recheck fluid
level with transmission at normal operating temperature. Adjust
fluid level to MAX mark on dipstick. Approximate drain and
refill capacity is 4.0 qts. (3.8L).
( 4) - Quantity may vary by type of oil cooler and oil cooler lines.
( 5) - Models with Trac-Lok limited slip differential must have 5 ozs.
(.15L) of Mopar Trac-Lok Friction Modifier added if lubricant is\
changed.
( 6) - Rear differential may be identified by number of bolts on rear
cover. The 8 1/4" ring gear has 10 bolts on rear cover and 9
1/4" ring gear has 12 bolts on rear cover.
( 7) - Use only Mopar power steering fluid. DO NOT use automatic
transmission fluid.
( 8) - Transfer case may be identified by model number stamped on
identification tag on rear of transfer case, just above filler
plug.









\









\









\









\









\









\









\







FLUID CAPACITIES (RAM PICKUP)








\









\









\









\









\









\









\







Application ( 1) Quantity
Crankcase (Includes Filter) ( 2)
3.9L ............................................. 4.0 Qts. (3.8L)\
5.2L & 5.9L (Gasoline) ........................... 5.0 Qts. (4.7L\
)
5.9L (Diesel) .................................. 11.0 Qts. (10.4L\
)
8.0L ............................................. 7.0 Qts. (6.6L)\
Cooling System (Includes Heater)
3.9L, 5.2L & 5.9L (Gasoline) ................... 20.0 Qts. (18.9L\
)
5.9L (Diesel) .................................. 24.0 Qts. (22.7L\
)
8.0L ........................................... 26.0 Qts. (24.6L)\
Automatic Transmission
(Mopar ATF Plus Type 7176)
42RE (3.9L)
Drain & Refill .............................. ( 3) 1.5 Qts. (1.4L)
Dry Refill ........................ ( 4) 8.5-11.0 Qts. (8.0-10.4L)
46RE (3.9L, 5.2L & 5.9L Gasoline)
Drain & Refill .............................. ( 3) 1.5 Qts. (1.4L)
Dry Refill ........................ ( 4) 9.5-11.5 Qts. (8.9-10.8L)
47RE (5.9L Diesel & 8.0L)
Drain & Refill .............................. ( 3) 1.5 Qts. (1.4L)
Dry Refill ...................... ( 4) 14.5-16.5 Qts. (13.7-15.6L)
Manual Transmission ( 5)
NV 3500 (Mopar M/T Lube,
P/N 4761526 - 3.9L & 5.2L) ...................... 2.1 Qts. (2.0L)\
NV 4500 (Mopar M/T Lube,
P/N 4637579) ( 6) - 5.9L
(Gas & Diesel) & 8.0L .......................... 4.0 Qts. (3.8L\
)
NV 5600 (Mopar M/T Lube,
P/N 4761526) ( 6) ............................... 4.75 Qts. (4.5L)
Front Differential (SAE 80W-90/API GL-5)
Dana 44 (Model 216 - 1500 & 2500) ................ 4.8 Pts. (2.3L\
)
Dana 60 (Model 248 - 2500 & 3500) ................ 7.6 Pts. (3.6L\
)
Rear Differential
9 1/4" Ring Gear
(SAE 75W-90/API
GL-5 - 1500 & 2500) ( 7) ........................ 4.8 Pts. (2.3L)
Dana 60 (Model 248)

Cooling System (Includes Heater)
3.9L ........................................... 14.6 Qts. (13.8L)\
5.2L ........................................... 16.5 Qts. (15.6L)\
5.9L
With Rear Heater .............................. 16.0 Qts. (15.1L)\
Without Rear Heater ........................... 15.0 Qts. (14.2L)\
Automatic Transmission (Mopar ATF Plus Type 7176)
32RH (3.9L)
Drain & Refill .............................. (3) 1.5 Qts. (1.4L)
Dry Refill .......................... ( 4) 8.5-8.8 Qts. (8.0-8.3L)
46RE (5.2L & 5.9L)
Drain & Refill .............................. ( 3) 1.5 Qts. (1.4L)
Dry Refill ...................... ( 4) 11.5-11.7 Qts. (10.8-11.1L)
Power Steering Fluid ( 5) ........................... 2.7 Pts. (1.3L)
Rear Differential
Dana 60
(Model 248 - SAE 90/API GL-5) ( 6)( 7) ............ 6.3 Pts. (2.9L)
8 1/4" & 9 1/4" Ring Gear
(SAE 80W-90/API GL-5) ( 8)( 9) .................... 4.8 Pts. (2.3L)
( 1) - Approximate quantity listed.
( 2) - Use an API energy conserving engine oil that is certified for
gasoline engines.
( 3) - Add this amount of fluid. Start engine and shift transmission
through all gears and back to Neutral. Add additional fluid to
bring fluid level to the MIN mark on dipstick. Recheck fluid
level with transmission at normal operating temperature. Adjust
fluid level to MAX mark on dipstick. Approximate drain and
refill capacity is 4.0 qts. (3.8L).
( 4) - Quantity may vary by type of oil cooler and oil cooler lines.
( 5) - Use only Mopar power steering fluid. DO NOT use automatic
transmission fluid.
( 6) - Rear differential may be identified by full-floating axles
shafts.
( 7) - Models with Trac-Lok limited slip differential must have 6 ozs.
(.18L) of Mopar Trac-Lok Friction Modifier added if lubricant is\
changed.
( 8) - Rear differential may be identified by number of bolts on rear
cover. The 8 1/4" ring gear has 10 bolts on rear cover and 9
1/4" ring gear has 12 bolts on rear cover.
( 9) - Models with Trac-Lok limited slip differential must have 5 ozs.
(.15L) of Mopar Trac-Lok Friction Modifier added if lubricant is\
changed.









\









\









\









\









\









\









\







QUICK-SERVICE
SERVICE INTERVALS & SPECIFICATIONS
REPLACEMENT INTERVALS (CARAVAN, TOWN & COUNTRY, & VOYAGER) ( 1)








\









\









\









\









\









\









\







Component Months Miles
Air Filter
Normal Service ..................... 24 ................. 30,000
Severe Service .................... ( 2) ............. ( 3) 15,000
Camshaft Timing Belt
2.4L
Normal Service .................... 96 ................ 120,000
Severe Service ................... ( 2) ................ 120,000
3.0L
Normal Service ( 4) ................ 48 ................. 60,000


E - T H EO RY/O PER ATIO N - D IE SEL

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Theory & Operation - Trucks - Diesel
Ram Pickup
INTRODUCTION
This article covers basic description and operation of engine
performance-related systems and components. Read this article before
diagnosing vehicles or systems with which you are not completely
familiar.
AIR INDUCTION SYSTEM
INTERCOOLER
NOTE: Intercooler may also be referred to as a charge air cooler.
Intercooler is a heat exchanger used to reduce intake air
temperature from turbocharger. Cooling of intake air results in an
increased air density for producing greater power and efficiency.
Intercooler is located in front of radiator. See Fig. 1.
Fig. 1: Exploded View Of Intercooler Assembly
Courtesy of Chrysler Corp.
TURBOCHARGER


E - T H EO RY/O PER ATIO N - R W D - G ASO LIN E

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Theory & Operation - Trucks & RWD Vans - Gasoline
Dakota, Durango, Ram Pickup, Ram Van, Ram Wagon
INTRODUCTION
This article covers the basic description and operation of
engine performance related systems and components. Read this article
before working on unfamiliar systems.
COMPUTERIZED ENGINE CONTROLS
POWERTRAIN CONTROL MODULE (PCM)
The PCM is a digital computer that controls ignition timing,
air/fuel ratio, fuel injector pulse width, ignition coil(s), spark
advance, emission control devices, cooling fan, charging system, idle
speed, cruise control (if equipped), fuel pump and tachometer. For PCM\
location, see PCM LOCATION. PCM uses data from various input sources
to control output devices in order to achieve optimum engine
performance for all operating conditions.
PCM has voltage converters that convert battery voltage to
regulated 5-volt output. The 5-volt output powers battery temperature
sensor, Camshaft Position (CMP) sensor on models equipped with
Distributorless Ignition System (DIS) or distributor on models without\
DIS, Crankshaft Position (CKP) sensor, Engine Coolant Temperature
(ECT) sensor, Intake Air Temperature (IAT) sensor, logic circuits,
Manifold Absolute Pressure (MAP) sensor, Throttle Position (TP) sens\
or
and Vehicle Speed Sensor (VSS) on some models.
PCM LOCATION









\









\









\









\









\









\









\







Application Location
Dakota & Durango ................. Right Front Fender, Near Firewall
Ram Pickup, Ram Van & Ram Wagon .... On Firewall, Near Wiper Motor









\









\









\









\









\









\









\







NOTE: Components are grouped into 2 categories. The first category,
INPUT DEVICES, includes components that control or produce
voltage signals monitored by the PCM. The second category,
OUTPUT SIGNALS, includes components controlled by the PCM
(this is accomplished by the PCM grounding individual
circuits).
INPUT DEVICES
Vehicles are equipped with different combinations of input
devices. Not all devices are used on all models. To determine
component location and input usage on a specific model, see
appropriate wiring diagram in WIRING DIAGRAMS article. Available input
signals include:
A/C Switch
Switch signals PCM that A/C has been selected. PCM then
activates A/C compressor clutch relay and maintains idle speed at a
preprogrammed RPM. This is done through control of Idle Air Control

drive plate. PCM uses this information to determine fuel injection
sequence, ignition signal and spark timing.
Cruise Control Switch
Cruise control switch provides PCM with 3 separate inputs.
ON/OFF switch input informs PCM that cruise control system has been
activated. SET/COAST switch input informs PCM that set vehicle speed
has been selected, or if depressed will decelerate until switch is
released. RESUME/ACCEL switch input informs PCM that a previously set
speed has been selected or, if depressed, will increase speed until
released. PCM uses these inputs to control cruise control servo.
Engine Coolant Temperature (ECT) Sensor
ECT sensor monitors engine coolant temperature. PCM uses ECT
sensor information to adjust air/fuel mixture and idle speed and to
control radiator cooling fans as necessary.
Fuel Level Sensor
PCM supplies a 5-volt reference signal to fuel module in gas
tank. Fuel level sensor sends a signal to PCM indicating fuel level.
PCM monitors this signal to prevent a false misfire signal if fuel
level is less than 15 percent. PCM also sends this signal to fuel
gauge.
Heated Oxygen Sensor (HO2S)
HO2S produces a small electrical voltage (0-1 volt) when
exposed to heated exhaust gas. HO2S is electrically heated for faster
warm-up. Heating element is powered through Auto Shutdown (ASD) relay.\
HO2S acts like a rich/lean (air/fuel ratio) switch by
monitoring oxygen content in exhaust gas. This information is used by
PCM to adjust air/fuel ratio by adjusting injector pulse width.
HO2S produces low voltage when oxygen content in exhaust gas
is high. When oxygen content in exhaust gas is low, HO2S produces a
higher voltage.
Ignition Switch
Ignition switch sends signal to PCM indicating whether switch
is on, off or cranking (ST). When PCM receives ON signal, it energizes\
ASD relay coil and supplies power to sensors and actuators. When PCM
receives ST signal, it controls fuel injection rate, idle speed,
ignition timing, etc. for optimum cranking conditions.
Intake Air Temperature (IAT) Sensor
IAT sensor measures temperature of incoming intake air. This
information is used by PCM to adjust air/fuel mixture.
Manifold Absolute Pressure (MAP) Sensor
MAP sensor monitors intake manifold vacuum. Sensor transmits
information on manifold vacuum and barometric pressure to PCM. MAP
sensor information is used with information from other sensors to
adjust air/fuel mixture.
Oil Pressure Sensor
Sensor sends a signal to PCM to indicate oil pressure.
Park/Neutral (P/N) Switch (A/T Models)
This switch may also be referred to as a Park/Neutral
Position (PNP) switch. P/N switch is available on vehicles equipped
with A/T only. Switch prevents engine starter from engaging if vehicle
is in any gear except Park or Neutral.
P/N switch input (varied with gear selection) is used to
determine idle speed, fuel injector pulse and ignition timing.

PCM.
MISCELLANEOUS CONTROLS
NOTE: Although not strictly considered part of engine performance
system, some controlled devices can adversely affect
driveability if they malfunction.
A/C CLUTCH RELAY
A/C clutch relay is controlled by PCM. When A/C or Defrost
mode is selected and PCM receives A/C request signal from evaporator
switch, PCM will cycle clutch on and off through A/C clutch relay.
When this relay is energized during engine operation, PCM will
determine correct engine idle speed through IAC motor.
When PCM senses low idle speed or wide open throttle through
TP sensor, PCM will de-energize A/C clutch relay, preventing A/C
operation.
AUTO SHUTDOWN (ASD) RELAY & FUEL PUMP RELAY
ASD relay and electric fuel pump relay are energized when
ignition is on. These relays are controlled through PCM by switching a
common ground circuit on and off. Following components are controlled
by ASD and fuel pump relays:
* Electric Fuel Pump
* Fuel Injectors
* Generator Field Winding
* Ignition Coil(s)
* HO2S Heating Element
When ignition switch is turned to RUN position, PCM energizes
ASD relay and electric fuel pump relay which powers these components.
If PCM does not receive a CMP and CKP sensor signal within one second
of engine cranking (start-up), PCM will turn ground circuit off and
de-energize ASD relay.
GENERATOR
Powertrain Control Module (PCM) regulates charging system
voltage.
LIMP-IN MODE
Limp-in mode is the attempt by PCM to compensate for failure
of certain components by substituting information from other sources
so that vehicle can still be operated. If PCM senses incorrect data or
no data at all from MAP sensor, TP sensor, ECT sensor or battery
voltage, system is placed into limp-in mode and Malfunction Indicator
Light (MIL) on instrument panel comes on.
If faulty sensor comes back on line, PCM will resume closed
loop operation. On some vehicles, MIL will remain on until ignition is
shut off and vehicle is restarted. To prevent damage to catalytic
converter, vehicle should NOT be driven for extended periods in limp-
in mode.
RADIATOR FAN RELAY
Electric cooling fan is used only on Dakota. Using
information supplied by A/C signal (if equipped), ECT sensor, and VSS,\

PCM controls operation of electric cooling fan. PCM operates fan
through radiator fan relay by grounding or ungrounding relay control
circuit. PCM regulates engine idle speed through IAC motor when fan is
on.
SHIFT INDICATOR LIGHT
PCM provides ground for shift indicator light on models
equipped with manual transmission. Based on engine speed, throttle
position, and vehicle speed, PCM turns shift indicator light on to
advise driver to shift to a higher gear for optimum fuel economy.
SPEED CONTROL SERVO
System is electrically actuated and vacuum operated. Controls
are located on steering wheel. Controls consist of 3 buttons: OFF/ON,
RESUME/ACCEL and SET/DECEL. Speed control servo is controlled by PCM.
System will operate at 35-85 MPH.
TACHOMETER
PCM provides signal to drive tachometer.
TORQUE CONVERTER CLUTCH (TCC) SOLENOID
PCM controls torque converter lock-up through TCC solenoid.
PCM controls lock-up according to various operating conditions.
TRANSMISSION GOVERNOR SOLENOID
PCM controls solenoid to regulate line pressure for shift
control.
TRANSMISSION OVERDRIVE/OVERRIDE (OD/OR) SWITCH INDICATOR
LIGHT
PCM controls indicator light on OD/OR switch on models
equipped with overdrive automatic transmission.
TRANSMISSION OVERDRIVE (OD) SOLENOID
On models equipped with OD transmission, PCM controls 3-4 OD
upshift and downshift through OD solenoid. PCM determines optimum OD
shift scheduling for all operating conditions.

bolster. Remove CTM from bracket on inboard side of instrument panel
steering column opening. Disconnect harness connectors. To install,
reverse removal procedure.
INTERMITTENT WIPER RELAY
Removal & Installation
Intermittent wiper relay is located in Power Distribution
Center (PDC) in engine compartment. Remove cover and remove relay. To
install, reverse removal procedures
WIPER ARMS
Removal & Installation
Open hood. Lift wiper and slide latch to hold wiper off of
windshield. With a rocking motion, remove wiper arm. To install,
ensure wiper motor is in park position. Slide wiper arm on shaft.
Align wiper arms. See WIPER BLADES under ADJUSTMENTS.
WIPER MOTOR
NOTE: Wiper linkage and motor module is replaced as a unit.
Removal & Installation
1) Disconnect negative battery cable. Remove wiper arms. See
WIPER ARMS. Remove weatherstrip along front edge of cowl. Release
plastic anchor screws. Lift cowl grille from vehicle. Remove washer
hose from "Y" fitting. Set grille aside.
2) Remove wiper linkage mounting bolts. Turn linkage over and
disconnect harness connector from wiper motor. Remove wiper linkage
and motor module. To install, reverse removal procedure. Align wiper
arms. See WIPER BLADES under ADJUSTMENTS.
WIPER/WASHER SWITCH
NOTE: Wiper/washer switch is part of multifunction steering column
switch. If wiper/washer switch fails, entire multifunction
switch must be replaced.
Removal & Installation
1) Disconnect negative battery cable. Remove tilt lever (if
equipped). Remove steering column upper and lower covers to access
switch connector. Remove switch connector. Remove multifunction switch
tamperproof screws.
2) Gently pull switch away from column and loosen connector
screw (screw remains in connector). Remove switch. To install, reverse\
removal procedure. Tighten screws and nuts to specification. See
TORQUE SPECIFICATIONS. Ensure switch is functioning properly.
WASHER RESERVOIR
Removal & Installation
Disconnect negative battery cable. Drain cooling system.
Disconnect upper radiator hose from radiator. Disconnect harness
connectors from washer pump and washer fluid level sensor. Remove
washer supply hose from washer pump and drain washer fluid. While
pulling reservoir away from fan shroud, lift reservoir upward to
disengage mounting tabs from fan shroud. Remove washer reservoir. To
install, reverse removal procedure.
WASHER MOTOR
Removal & Installation