key DODGE RAM 1999 Service Manual PDF
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
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IGNITION SWITCHES
INDICATOR LIGHTS
KEYLESS ENTRY KEYPADS AND TRANSMITTERS
KEYLESS ENTRY TRANSMITTERS
LEDS
LENSES
MICROPHONES
MIRRORS (ELECTROCHROMATIC AND HEATED)
MOTORS
NEUTRAL SAFETY SWITCHES
ODOMETERS
ODOMETERS, SPEEDOMETERS AND TACHOMETERS (CABLE-DRIVEN)
PULLEYS
RECEIVERS, AMPLIFIERS, EQUALIZERS AND SUB-WOOFER VOLUME CONTROLS
RELAY BOXES
RELAYS
SEALED BEAMS
SEAT HEATERS
SECURITY ALARM SENSORS
SIRENS
SOLENOIDS
SPEAKERS AND MICROPHONES
SPEEDOMETER AND TACHOMETER LINKAGES AND CABLES
SPEEDOMETER CABLES
SPEEDOMETERS
STARTERS
SUB-WOOFER VOLUME CONTROLS
SWITCHES
TACHOMETER CABLES
TACHOMETERS
TAPE PLAYERS AND CD PLAYERS
TENSIONERS
TIMERS
TIRE PRESSURE SENSORS
TRANSCEIVERS
TRANSDUCERS
VACUUM ACCUMULATORS (RESERVOIRS)
VACUUM RESERVOIRS
VOLTAGE REGULATORS
WASHER FLUID LEVEL SENDERS
WASHER PUMPS
WIPER ARMS AND BLADES
WIPER BLADES
WIPER HOSES AND NOZZLES
WIPER LINKAGES
WIPER NOZZLES
WIPER PUMP RESERVOIRS
WIRING HARNESSES AND CONNECTORS
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
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On intermittently ....... .. ......... (1) Further inspection
required.
( 1) - See service manual for further information.
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KEYLESS ENTRY KEYPADS AND TRANSMITTERS
KEYLESS ENTRY KEYPAD AND TRANSMITTER INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Malfunctioning .......... A ........... ( 2) Require repair or
replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Wire lead burned ........ A .. Require repair or replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Malfunctioning includes inoperative, intermittent
operation, or failure to perform all functions.
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KEYLESS ENTRY TRANSMITTERS
See KEYLESS ENTRY KEYPADS AND TRANSMITTERS .
LEDS
See BULBS, SEALED BEAMS AND LEDS .
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Condition Code Procedure
Application incorrect ... B ........... Require replacement.
Fails to maintain proper
pressure ............... A ........... Require replacement.
Gaskets missing ......... C ........... Require replacement.
Leaking ................. A ........... Require replacement.
Missing ................. C ........... Require replacement.
Plugged (vacuum and
pressure relief) ....... A ........... Require replacement.
Seals missing ........... C ........... Require replacement.
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GASKETS
GASKET INSPECTION \
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Condition Code Procedure
Leaking ................. A ........... ( 1) Require repair or
replacement.
( 1) - Require inspection of mating and sealing surface and
repair or replace as necessary.
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GROMMETS (VALVE COVER)
GROMMET (VALVE COVER) INSPECTION \
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Condition Code Procedure
Leaking ................. 2 ........... ( 1) Suggest repair or
replacement.
( 1) - Require inspection of mating and sealing surface and
repair or replace as necessary.
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HARMONIC DAMPERS
HARMONIC DAMPER INSPECTION \
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Condition Code Procedure
Application incorrect ... B ........... Require replacement.
Attaching hardware
broken ................. A .. Require repair or replacement
of hardware.
Attaching hardware
missing ................ C ......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A .. Require repair or replacement
of hardware.
Cracked ................. A ........... Require replacement.
Dented (fluid
type only) ............. A ........... Require replacement.
Keyway distorted ........ A . Require repair or replacement.
Leaking (Fluid damper
only) .................. A ........... Require replacement.
Loose ................... A ........... Require replacement.
Noisy ................... A ........... Require replacement.
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Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable;
check for accepted cleaning procedure.
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TIMING BELT SPROCKETS
TIMING BELT SPROCKET INSPECTION \
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Condition Code Procedure
Alignment incorrect ..... B ................. Require repair.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Bent .................... A ............ Require replacement.
Cracked ................. A ............ Require replacement.
Key damaged ............. A ............ Require replacement.
Loose ................... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Pulley damaged, affecting
belt life .............. A ............ Require replacement.
Sprocket damaged,
affecting belt life .... A .. Require repair or replacement.
Sprocket loose .......... B .. Require repair or replacement.
Sprocket-to-shaft
alignment incorrect ..... B .. Require repair or replacement.
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TIMING BELTS
TIMING BELT INSPECTION \
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Condition Code Procedure
Adjustment incorrect .... 2 ......... ( 1) Suggest adjustment.
Alignment incorrect ..... B ........... ( 2) Further inspection
required.
Broken .................. A ............ Require replacement.
Cam timing out of
specification .......... B ................. Require repair.
Cracked ................. 1 ............ Suggest replacement.
Fluid-soaked ............ 1 ... Suggest replacement. Further
inspection required.
Frayed .................. 1 ............ Suggest replacement.
Maintenance intervals ... 3 ... Suggest replacement to comply
with vehicle OEM recommended
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![DODGE RAM 1999 Service Manual PDF Brake On/Off (BOO) Switch ................... Cruise Control Systems\
Engine Performance
Shift Int](/img/12/56915/w960_56915-849.png "DODGE RAM 1999 Service Manual PDF Brake On/Off (BOO) Switch ................... Cruise Control Systems\
Engine Performance
Shift Int")
Brake On/Off (BOO) Switch ................... Cruise Control Systems\
Engine Performance
Shift Interlock Systems
Buzzer Module ...................................... Warning Systems
Camshaft Position (CMP) Sensor .................. Engine Performance\
Central Control Module ........................... Anti-Theft System
Clockspring ............................... Air Bag Restraint System
Cruise Control Systems
Steering Column Switches
Clutch Pedal Position Switch .............................. Starters
Clutch Start Switch ....................................... Starters
Combination Meter ......................... Analog Instrument Panels
Constant Control Relay Module (CCRM) ............ Engine Performance\
Electric Cooling Fans
Convenience Center .............................. Power Distribution
Illumination/Interior Lights
Convertible Top Motor ........................ Power Convertible Top
Convertible Top Switch ....................... Power Convertible Top
Crankshaft Position (CKP) Sensor ................ Engine Performance\
Cruise Control Module ....................... Cruise Control Systems
Cruise Control Switch ....................... Cruise Control Systems
Condenser Fan Relay(s) ....................... Electric Cooling Fans\
Data Link Connector (DLC) ....................... Engine Performance\
Daytime Running Lights Module ............... Daytime Running Lights
Exterior Lights
Defogger Relay ................................ Rear Window Defogger
Diagnostic Energy Reserve Module (DERM) ... Air Bag Restraint System\
Discriminating Sensor (Air Bag) ........... Air Bag Restraint System\
Distributor ..................................... Engine Performance
Door Lock Actuators ............................... Power Door Locks
Remote Keyless Entry
Door Lock Relay(s) ................................ Power Door Locks\
Electrochromic Mirror ................................ Power Mirrors
Electronic Level Control (ELC)
Height Sensor .............................. Electronic Suspension
Electronic Level Control (ELC) Module ........ Electronic Suspension\
Engine Coolant Temperature (ECT)
Sending Unit ............................ Analog Instrument Panels
Engine Coolant Temperature (ECT) Sensor ......... Engine Performance\
Engine Control Module ........................... Engine Performance
Generators & Regulators
Starters
ETACS ECU .......................................... Warning Systems
Power Windows
Remote Keyless Entry
Evaporative (EVAP) Emissions Canister ........... Engine Performance\
EVAP Canister Purge Solenoid .................... Engine Performance
EVAP Canister Vent Solenoid ..................... Engine Performance
Exhaust Gas Recirculation (EGR) Valve ........... Engine Performance\
Fuel Tank Vacuum Sensor ......................... Engine Performance
Fog Lights ....................................... Headlight Systems
Daytime Running Lights
Fog Light Relay .................................. Headlight Systems
Daytime Running Lights
Fuel Door Release Solenoid ................. Power Fuel Door Release
Fuel Gauge Sending Unit ................... Analog Instrument Panels
Fuel Injectors .................................. Engine Performance
Fuel Pump ....................................... Engine Performance
Fuel Pump Relay ................................. Engine Performance
Power Distribution
Fuse/Relay Block ................................ Power Distribution
Fusible Links ................................... Power Distribution
Generators & Regulators
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Starters
Generator .................................. Generators & Regulators
Engine Performance
Power Distribution
Generic Electronic Module (GEM) ............... Body Control Modules\
Electronic Suspension
Glow Plug Relay ................................. Engine Performance
Glow Plugs ...................................... Engine Performance
Grounds ........................................ Ground Distribution
Headlight Door Module .............................. Headlight Doors
Headlight Relay .................................. Headlight Systems
Daytime Running Lights
Headlights ....................................... Headlight Systems
Daytime Running Lights
Heated Oxygen Sensor(s) (HO2S) .................. Engine Performan\
ce
Heated Windshield Control Module ................ Heated Windshields
Height Sensor ................................ Electronic Suspension
Horns ..................................... Steering Column Switches
Horn Relay ................................ Steering Column Switches
Idle Air Control (IAC) Motor/Valve .............. Engine Performance\
Ignition Coil(s) ................................ Engine Performance\
Ignition Key Lock Cylinder ....................... Anti-Theft System
Ignition Module ................................. Engine Performance
Ignition Switch ................................. Power Distribution
Engine Performance
Generators & Regulators
Starters
Illuminated Entry Module .............. Illumination/Interior Lights
Illumination Lights ................... Illumination/Interior Lights
Impact Sensor ............................. Air Bag Restraint System
Inertia Fuel Shutoff Switch ..................... Engine Performance
Inhibit Relay ............................................. Starters
Instrument Cluster ........................ Analog Instrument Panels
Intake Air Temperature (IAT) Sensor ............. Engine Performance\
Interior Lights ....................... Illumination/Interior Lights
Interlock Switch .......................................... Starters
Junction Block .................................. Power Distribution
Keyless Entry Receiver ........................ Remote Keyless Entry
Key Reminder Switch ....................................... Starters
Knock Sensor .................................... Engine Performance
Lamp Control Module ................................ Exterior Lights
License Plate Lamp ................................. Exterior Lights
Lighting Control Module ................... Lighting Control Modules
Anti-Theft System
Daytime Running Lights
Headlight Systems
Lower Relay .................................. Power Convertible Top
Malfunction Indicator Light (MIL) ............... Engine Performance\
Instrument Panels
Manifold Absolute Pressure (MAP) Sensor ......... Engine Performance\
Mass Airflow (MAF) Sensor ....................... Engine Performance\
Mega Fuse .................................. Generators & Regulators
Memory Seat/Mirror Module ........................... Memory Systems
Mirror Defogger ............................... Rear Window Defogger
Moon Roof Motor .................................... Power Moon Roof
Moon Roof Relay .................................... Power Moon Roof
Multi-Function Control Module ...................... Warning Systems
Neutral Safety Switch ..................................... Starters
Oil Level Switch ................................ Engine Performance
Oil Pressure Switch/Sending Unit .......... Analog Instrument Panels
Engine Performance
Overhead Console .................................. Overhead Console
Oxygen Sensor(s) (O2S) .......................... Engine Performan\
ce
Page 893 of 1691
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
Page 894 of 1691
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
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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.
Page 917 of 1691
PA R ASIT IC L O AD E XPLA N ATIO N & T E ST P R O CED URES
1999 D odge P ic ku p R 1500
GENERAL INFORMATION
Parasitic Load Explanation & Test Procedures
* PLEASE READ THIS FIRST *
This article is provided for general information only. Not
all procedures apply to all makes and models.
GENERAL INFORMATION
The term Parasitic Load refers to electrical devices that
continue to use or draw current after the ignition switch is turned to
OFF position. This small amount of continuous battery draw is
expressed in milliamps (mA). On Ford Motor Co. and General Motors
vehicles produced after 1980, a typical Parasitic Load should be no
more than 50 milliamps (0.050 amps).
Vehicles produced since 1980 have memory devices that draw
current with ignition off for as long as 20 minutes before shutting
down the Parasitic Drain. When Parasitic Load exceeds normal
specifications, the vehicle may exhibit dead battery and no-start
condition.
Follow test procedure for checking Parasitic Loads to
completion. A brief overview of a suggested test procedure is included
along with some typical Parasitic Load specifications. Refer to the
GENERAL MOTORS PARASITIC LOAD TABLE chart.
TESTING FOR PARASITIC LOAD
INTRODUCTION
CAUTION: Always turn ignition off when connecting or disconnecting
battery cables, battery chargers or jumper cables. DO NOT
turn test switch to OFF position (which causes current to run
through ammeter or vehicle electrical system).
NOTE: Memory functions of various accessories must be reset after
the battery is reconnected.
The battery circuit must be opened to connect test switch
(shunt) and ammeter into the circuit. When a battery cable is removed,\
timer circuits within the vehicle computer are interrupted and
immediately begin to discharge. If in doubt about the condition of the
ammeter fuse, test it with an ohmmeter prior to beginning test. An
open fuse will show the same reading (00.00) as no parasitic drain.
Begin test sequence with the meter installed and on the 10-amp scale.
Select lower scale to read parasitic draw.
TEST PROCEDURE USING TEST SWITCH
1) Turn ignition off. Remove negative battery terminal cable.
Install Disconnect Tool (J-38758) test switch male end to negative
battery cable. Turn test switch knob to OFF position (current through
meter). Install negative battery cable to the female end of test
switch.
2) Turn test switch knob to ON position (current through
switch). Road test vehicle with vehicle accessories on (radio, air
conditioner, etc.). After road test, turn ignition switch to LOCKED
position and remove key. Connect ammeter terminals to test switch