ABS 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
Page 950 of 1691
Fig. 8: Locating Manifold Absolute Pressure (MAP) 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. 9: Locating Manifold Absolute Pressure (MAP) Sensor (Ram
Pickup 8.0L)
Courtesy of Chrysler Corp.
OIL PRESSURE SENSOR
Page 953 of 1691
Removal & Installation (Ram Pickup)
PTO switch is used on models only with after market PTO
units. PTO switch delivers an input signal to Powertrain Control
Module (PCM) to indicate when PTO is engaged. The PCM will disable
certain OBD-II systems when PTO is engaged. No other service
information is available from manufacturer.
THROTTLE POSITION (TP) SENSOR
Removal (Dakota, Durango, Ram Pickup 3.9L, 5.2L & 5.9L, Ram
Van & Ram Wagon)
The TP sensor is located on side of throttle body. On Ram Van
and Ram Wagon, remove engine cover. On all models, remove air inlet
duct at throttle body for access to TP sensor. Disconnect electrical
connector at TP sensor. Remove retaining bolts and TP sensor.
Installation
1) Throttle shaft on throttle body slides into socket on TP
sensor. Throttle shaft rests against tabs in socket on TP sensor. See
Fig. 12 .
2) Install TP sensor on throttle body. When properly
installed, TP sensor should rotate a few degrees so retaining bolts
may be installed. Slight tension should exist on TP sensor when
rotating TP sensor.
3) If difficult to rotate TP sensor into position when
aligning retaining bolts, remove TP sensor. Reinstall TP sensor so
throttle shaft is on the other side of tabs in socket on TP sensor.
Tighten retaining bolts for TP sensor to specification. See TORQUE
SPECIFICATIONS.
4) Operate throttle lever on throttle body to ensure no
binding exists in TP sensor. Install electrical connector and air
inlet duct or air cleaner assembly.
Removal (Ram Pickup 8.0L)
The TP sensor is located on side of throttle body. Remove air
inlet duct at air cleaner assembly. Remove cover from air cleaner
assembly. Remove air cleaner housing-to-throttle body nuts and air
cleaner housing from throttle body. Disconnect electrical connector at
TP sensor. Remove retaining bolts and TP sensor.
Installation
1) Throttle shaft on throttle body slides into socket on TP
sensor. Throttle shaft rests against tabs in socket on TP sensor. See
Fig. 12 .
2) Install TP sensor on throttle body. When properly
installed, TP sensor should rotate a few degrees so retaining bolts
may be installed. Slight tension should exist on TP sensor when
rotating TP sensor.
3) If difficult to rotate TP sensor into position when
aligning retaining bolts, remove TP sensor. Reinstall TP sensor so
throttle shaft is on the other side of tabs in socket on TP sensor.
Tighten retaining bolts for TP sensor to specification. See TORQUE
SPECIFICATIONS.
4) Operate throttle lever on throttle body to ensure no
binding exists in TP sensor. To install remaining components, reverse
removal procedure. Tighten air cleaner housing-to-throttle body nuts
to specification. See TORQUE SPECIFICATIONS.
Page 971 of 1691
N - R EM OVE /IN STA LL/O VER HAU L
under FUEL SYSTEM. Disconnect negative battery cable. Ensure disconnect fitting and fuel lines are clean. Note location of releasetab and pull tab on disconnect fitting. See Fig. 24.
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. Removedisconnect fitting from fuel line. Inspect components for damage. Ifdisconnect fitting is damaged, entire assembly must be replaced, asonly pull tab may be replaced. 3) To install, ensure fuel line and disconnect fitting areclean. Lubricate fuel line and disconnect fitting with engine oil.Install disconnect fitting on fuel line until disconnect fittingbottoms on fuel line. 4) Install NEW pull tab until pull tab locks in disconnectfitting. DO NOT reuse old pull tab. Pull on fuel line and disconnectfitting to ensure components are properly locked together. Reconnectnegative battery cable. Start engine and check for leaks. Removal & Installation (Dual Tab)
1) Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM. Disconnect negative battery cable. Ensuredisconnect fitting and fuel lines are clean. Note location of tabs ondisconnect fitting. See Fig. 24.
2) Squeeze both tabs against disconnect fitting. Pulldisconnect fitting from fuel line. The plastic retainer will remain onthe fuel system component being serviced. The "O" rings and spacerwill remain in the disconnect fitting. 3) Inspect components for damage. If disconnect fitting isdamaged, entire assembly must be replaced. The only component that maybe replaced is the plastic retainer. If plastic retainer must beremoved from fuel system component, carefully release the plasticretainer from the fuel system component using 2 screwdrivers. Inspectplastic retainer for cracks or damage. Replace plastic retainer ifdefective. 4) To install, ensure fuel line and disconnect fitting areclean. 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 ensurecomponents are properly locked together. Reconnect negative batterycable. Start engine and check for leaks. Removal & Installation (Plastic Retainer Ring)
1) Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM. Disconnect negative battery cable. Ensuredisconnect fitting and fuel lines are clean. Note location of plasticretainer ring on disconnect fitting. See Fig. 24.
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. Withplastic retainer ring fully depressed, pull disconnect fitting fromfuel line. 3) Inspect components for damage. If disconnect fitting isdamaged, entire assembly must be replaced. 4) To install, ensure fuel line and disconnect fitting areclean. Lubricate fuel line and disconnect fitting with engine oil.Install disconnect fitting on fuel line until click sound is heard.
Page 978 of 1691
Removal & Installation
Fuel pressure regulator is incorporated with the fuel filter.
For servicing for fuel filter/fuel pressure regulator, see FUEL
FILTER/FUEL PRESSURE REGULATOR.
FUEL PUMP
Removal & Installation
Fuel pump is incorporated into the fuel pump module. See FUEL
PUMP MODULE.
FUEL PUMP INLET STRAINER
Removal & Installation
1) Fuel pump inlet strainer is mounted on fuel pump module.
See Fig. 31 . Remove fuel pump module. See FUEL PUMP MODULE.
2) Spread locking tabs on bottom of fuel pump module and
remove fuel pump inlet strainer from fuel pump module. See Fig. 31.
Remove "O" ring from end of fuel pump module if "O" ring was not
removed with fuel pump inlet strainer.
3) To install, reverse removal procedure. Ensure "O" ring is
properly seated when installing fuel pump inlet strainer. Reinstall
fuel pump module using proper procedure.
FUEL PUMP MODULE
Removal (Dakota)
1) Fuel pump module is located on top of fuel tank. See
Fig. 27 . Fuel tank must be removed for servicing of fuel pump module.
Remove fuel tank. See FUEL TANK.
2) Ensure area around fuel pump module is clean. Using Fuel
Pump Module Lock Nut Spanner Wrench (6856), remove fuel pump module
lock nut. See Fig. 32. Remove fuel pump module with rubber gasket from
fuel tank.
CAUTION: When fuel pump module is removed from fuel tank, rubber
gasket must be replaced. DO NOT reuse rubber gasket.
Installation
1) Ensure sealing area on fuel tank is clean. Using NEW
rubber gasket, install fuel pump module on fuel tank. DO NOT reuse
rubber gasket. Ensure rubber gasket remains in place.
NOTE: Fuel pump module must be properly positioned in fuel tank to
prevent float from contacting the fuel tank.
2) Rotate fuel pump module so alignment arrow on fuel pump
module is at 7 o'clock position and aligns with reference mark on fuel
tank. See Fig. 33. Install and hand tighten fuel pump module lock nut.
3) Note location of fuel pressure regulator on fuel pump
module. See Fig. 27. Ensure fuel filter/pressure regulator is
positioned on fuel pump module so fuel line fitting on side fuel
filter/fuel pressure regulator points toward driver's side of vehicle.
4) Hold fuel pump module in place while tightening fuel pump
module lock nut to specification. See TORQUE SPECIFICATIONS. Reinstall
fuel tank using proper procedure.
Page 984 of 1691
regulator on fuel pump module using proper procedure for fuel line
disconnect fitting. See FUEL LINE DISCONNECT FITTINGS. Fuel pump
module is located on top of fuel tank. See Fig. 27. Disconnect
electrical connector at fuel pump module. Disconnect vapor line from
rollover valve on top of fuel tank.
8) Lower fuel tank from vehicle. If necessary to drain fuel
tank or to remove fuel tank filler tube assembly from fuel tank, go to
next step.
9) Ensure area around disconnect fitting at fuel tank for
fuel tank filler tube assembly is clean. See Fig. 27. The small vent
tube on fuel tank filler tube assembly should be removed first.
CAUTION: Disconnect fitting on small vent tube and large fill tube
must be fully pressed onto fuel tank fitting before pushing
release sleeve into disconnect fitting. Failure to fully
press disconnect fitting fully onto fuel tank fitting will
result in damage to retaining tabs in disconnect fitting.
10) Push disconnect fitting on end of small vent tube toward
fitting fuel tank as far as possible. See Fig. 37. Ensure disconnect
fitting is fully pressed onto fuel tank fitting before attempting to
push release sleeve into disconnect fitting.
11) Push release sleeve upward into disconnect fitting as far
as possible to release the retaining tabs in disconnect fitting. See
Fig. 37 . Ensure release sleeve is pushed evenly into disconnect
fitting. Pull small vent tube with disconnect fitting from fuel tank.
Drain remaining fuel from fuel tank into an approved gasoline
container if necessary.
12) If necessary to remove large fill tube from fuel tank,
push disconnect fitting on end of large fill tube toward fitting fuel
tank as far as possible. See Fig. 37. Ensure disconnect fitting is
fully pressed onto fuel tank fitting before attempting to push release
sleeve into disconnect fitting.
13) Push release sleeve upward into disconnect fitting as far
as possible to release the retaining tabs in disconnect fitting. See
Fig. 37 . Ensure release sleeve is pushed evenly into disconnect
fitting. Pull large fill tube with disconnect fitting from fuel tank.
Fig. 37: Removing & Installing Disconnect Fittings On Fuel Tank
Fitting (Dakota)
Courtesy of Chrysler Corp.
Installation
Page 987 of 1691
pump to drain the fuel tank, go to next step.
2) Disconnect fuel line from fuel rail. See FUEL LINE AT FUEL
RAIL. Connect Fuel Hose (6541, 6539, 6631 or 6923) for proper engine
application at fuel line fitting on fuel rail. Place remaining end of
fuel hose in an approved gasoline container.
3) Connect scan tool to Data Link Connector (DLC). DLC is a
16-pin connector attached to bottom of driver's side of the instrument
panel, just straight above the accelerator pedal. Using scan tool
manufacturer's instructions, activate the fuel pump and pump fuel from
fuel tank. Once fuel tank is empty, remove scan tool. Reinstall fuel
line on fuel rail using proper procedure. Go to step 5).
4) Release fuel pressure from fuel system. See FUEL SYSTEM
PRESSURE RELEASE. Ensure negative battery cable is disconnected.
Remove fuel tank cap to release any residual fuel tank pressure.
5) Raise and support vehicle. Disconnect the small vent hose
from fill and vent hose fitting assembly at driver's side frame rail.
Fill and vent hose fitting assembly is permanently attached on fuel
tank. See Fig. 30.
6) If fuel tank was previously drained, go to next step. If
fuel tank was not previously drained, siphon fuel from fuel tank into
an approved gasoline container by installing siphon hose in small vent
hose fitting on fill and vent hose fitting assembly. Go to next step.
7) Disconnect large fill hose from fill and vent hose fitting
assembly at driver's side frame rail. Fill and vent hose fitting
assembly is permanently attached on fuel tank. See Fig. 30.
8) Support fuel tank with transmission jack. Remove fuel tank
strap retaining nuts from L-shaped bolts securing fuel tank straps on
frame rail. Remove fuel tank straps.
CAUTION: Fill and vent hose fitting assembly must be released from
plastic shield before lowering fuel tank. Use care when
lowering fuel tank as not to damage fill and vent hose
fitting assembly or the fuel tank.
9) Fill and vent hose fitting assembly is permanently
attached on fuel tank and is protected from the frame by a plastic
shield. See Fig. 30. Push retaining tabs inward to release fill and
vent hose fitting assembly from the plastic shield before lowering the
fuel tank. See Fig. 38.
Fig. 38: Releasing Retaining Tabs From Plastic Shield (Ram Van &
Ram Wagon)
Courtesy of Chrysler Corp.
10) Slightly lower fuel tank while guiding fill and vent hose
Page 988 of 1691
fitting assembly out of the plastic shield. Use care not to damage
fill and vent fitting assembly. Disconnect fuel line from fuel
filter/fuel pressure regulator on fuel pump module using proper
procedure for fuel line disconnect fitting. See FUEL LINE DISCONNECT
FITTINGS. Fuel pump module is located on top of fuel tank. See Fig. 30
.
11) Disconnect electrical connector at fuel pump module.
Disconnect vapor hoses from rollover valves on top of fuel tank. See
Fig. 30 . Lower fuel tank from vehicle. Use care not to damage fill and
vent hose fitting assembly.
Installation
1) To install, reverse removal procedure. Install fuel lines
on fuel filter/fuel pressure regulator on fuel pump module using
proper procedure. See FUEL LINE DISCONNECT FITTINGS.
2) Ensure retaining tabs on fill and vent hose fitting
assembly fully engage the plastic shield. Tighten fuel tank strap
retaining nuts to specification. See TORQUE SPECIFICATIONS. Start
engine and check for fuel leaks.
FUEL RAIL & INJECTORS
Removal (Dakota 2.5L)
1) Release fuel pressure from fuel system. See FUEL SYSTEM
PRESSURE RELEASE. Ensure negative battery cable is disconnected.
2) Disconnect air inlet duct at throttle body for access to
fuel rail. Disconnect vent line from fuel damper at end of fuel rail
(if equipped).
3) Note electrical connector location on injectors for
installation reference. Disconnect electrical connectors at injectors.
Disconnect fuel line from fuel rail. See FUEL LINE AT FUEL RAIL.
Disconnect control cables at throttle body. Remove control cable
mounting bracket from intake manifold for access to fuel rail.
4) Remove fuel rail bolts. Ensure area around injectors and
intake manifold is clean. Using rocking motion, remove fuel rail with
injectors from intake manifold.
5) If removing injector from fuel rail, remove retaining clip
from fuel rail and injector. Retaining clip is located at top of
injector and fuel rail. Remove injector with "O" ring from fuel rail.
Installation
1) If installing injector on fuel rail, install NEW "O" ring
on injector. Coat "O" ring on injector with engine oil. Install
injector on fuel rail. Install retaining clip on injector and fuel
rail.
2) To install remaining components, reverse removal procedure
using NEW "O" ring at bottom of each injector. Coat "O" ring on
injector with engine oil before installing injectors and fuel rail.
3) Tighten fuel rail bolts to specification. See TORQUE
SPECIFICATIONS. Install fuel line on fuel rail using proper procedure.
See FUEL LINE AT FUEL RAIL. Start engine and check for leaks.
Removal (Dakota 3.9L, 5.2L & 5.9L, Durango, Ram Pickup 3.9L,
5.2L & 5.9L, Ram Van & Ram Wagon)
1) Release fuel pressure from fuel system. See FUEL SYSTEM
PRESSURE RELEASE. Ensure negative battery cable is disconnected.
2) On Ram Van and Ram Wagon, remove engine cover. On all
models, remove air cleaner. Remove throttle body from intake manifold.
See THROTTLE BODY. On A/C equipped models, remove A/C compressor-to-
intake manifold support brace at rear of A/C compressor.
3) On all models, note electrical connector location on
injectors for installation reference. Disconnect electrical connectors
at injectors. Disconnect any necessary wiring electrical connectors
Page 991 of 1691
body. Remove throttle body bolts, throttle body and gasket. To
install, reverse removal procedure using NEW gasket. Tighten throttle
body bolts to specification. See TORQUE SPECIFICATIONS.
Removal & Installation (Ram Pickup 8.0L)
1) Remove air cleaner cover. Remove air cleaner housing-to-
throttle body nuts and air cleaner housing from throttle body.
Disconnect electrical connectors, control cables and vacuum hoses at
throttle body. Remove throttle body nuts, throttle body and gasket
from upper intake manifold.
2) To install, reverse removal procedure using NEW gasket.
Tighten throttle body nuts and air cleaner housing-to-throttle body
nuts to specification. See TORQUE SPECIFICATIONS.
EMISSION SYSTEMS
EVAP CANISTER
Removal & Installation (Dakota & Durango)
1) EVAP canister is located on mounting bracket attached to
inside of driver's side frame rail, just in front of the fuel tank.
Raise and support vehicle.
2) Note location of vacuum hoses on EVAP canister for
installation reference. Disconnect vacuum hoses from EVAP canister.
Remove EVAP canister-to-mounting bracket nut and EVAP canister.
3) To install, reverse removal procedure. Ensure the pins on
EVAP canister engage with grommets on mounting bracket. Tighten EVAP
canister-to-mounting bracket nut to specification. See TORQUE
SPECIFICATIONS.
Removal & Installation (Ram Pickup)
1) Two EVAP canisters are used. EVAP canisters are located on
mounting bracket attached to outside of passenger's side frame rail,
just behind the cab.
2) Note location of vacuum hoses on EVAP canister for
installation reference. Disconnect vacuum hoses from EVAP canister.
Remove EVAP canister-to-mounting bracket nuts and EVAP canisters.
3) To install, reverse removal procedure. Tighten EVAP
canister-to-mounting bracket nut to specification. See TORQUE
SPECIFICATIONS.
Removal & Installation (Ram Van & Ram Wagon)
1) Two EVAP canisters are used. EVAP canisters are located on
mounting bracket under driver's side of vehicle, behind driver's side
door opening.
2) Remove nuts and EVAP canister mounting bracket from the
body. Slightly lower EVAP canisters. Note location of vacuum hoses on
EVAP canister for installation reference. Disconnect vacuum hoses from
EVAP canister. Remove EVAP canister-to-mounting bracket nuts and EVAP
canisters.
3) To install, reverse removal procedure. Tighten EVAP
canister-to-mounting bracket nut to specification. See TORQUE
SPECIFICATIONS. When installing mounting bracket, ensure locating tabs
at top of mounting bracket engage with openings on the body. Tighten
EVAP canister mounting bracket-to body nuts to specification. See
TORQUE SPECIFICATIONS.
EVAP LEAK DETECTION PUMP
NOTE: EVAP leak detection pump may also be referred to as Leak
Detection Pump (LDP).
Page 1245 of 1691
assembly to steering knuckle. Finger tighten bolts. Install 2
remaining rotor and hub assembly bolts. Tighten all bolts to
specification.
5) Install rotor and hub nut. Tighten nut to specification.
See TORQUE SPECIFICATIONS. Install cotter pin. On one ton models,
install adapter hub bolts and hub to rotor and hub assembly. Install
brake caliper, and tighten bolts to specification. Install wheels, and
tighten lug nuts to specification.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application (1) Ft. Lbs. (N.m)
ABS Sensor Bolt ............................................ 15 (11)\
Brake Caliper Bolt ......................................... 38 (52)\
Drag Link Nut .............................................. 65 (88)\
Hub-To-Steering Knuckle Bolt ..................... 125-160 (170-217)\
Lower Ball Joint Nut
216 FBI ................................................. 80 (108)\
248 FBI ........................................ 140-160 (190-217)\
Rotor & Hub Nut .................................. 160-200 (217-271)\
Shock Absorber Lower Bolt ................................ 100 (136)\
Stabilizer Bar Bolt ........................................ 27 (37)\
Tie Rod-To-Steering Knuckle Nut ............................ 65 (88)\
Upper Ball Joint Nut
216 FBI ................................................. 75 (102)\
248 FBI .................................................. 70 (94)\
Wheel Lug Nuts .................................... 95-145 (130-195)\
( 1) - Front axles can be identified by differential cover. The 216 FBI
has rounded edges, the 248 FBI has flat angled edges.
\
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Page 1259 of 1691
* S TE ER IN G U NIF O RM IN SPEC TIO N G UID ELIN ES *
1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
Steering, Suspension, Wheel Alignment, Wheels and Tires
Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Steering and Suspension
AIR RIDE SUSPENSION
AIR RIDE SUSPENSION - AIR SHOCKS AND AIR STRUTS
AIR RIDE SUSPENSION - AIR SPRING VALVES
AIR RIDE SUSPENSION - AIR SPRINGS
AIR RIDE SUSPENSION - COMPRESSORS
AIR RIDE SUSPENSION - HEIGHT SENSORS
AIR RIDE SUSPENSION - MODULES
AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)
AIR RIDE SUSPENSION - SWITCHES (ON/OFF)
AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)
AIR RIDE SUSPENSION - TUBING
AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SUSPENSION - WIRING HARNESSES
BALL JOINTS
BUSHINGS
CENTER LINKS
CONTROL ARM SHAFTS
CONTROL ARMS
DRAG LINKS
ELECTRONIC RIDE CONTROL SHOCKS AND STRUTS
IDLER ARMS
KING PINS
PITMAN ARMS
POWER STEERING HOSES
POWER STEERING (HYDRAULIC) PUMPS
RADIUS ARMS
RELAY RODS
SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
SPINDLES
SPRINGS - COIL, LEAF AND TORSION BAR
STEEL POWER STEERING LINES
STEERING ARMS
STEERING DAMPERS
STEERING GEARS (EXCEPT RACK AND PINION)
STEERING GEARS - RACK AND PINION
STEERING KNUCKLES
STRIKE OUT BUMPERS
STRUT RODS
STRUT UPPER BEARING PLATE ASSEMBLIES
SWAY BAR LINKS
SWAY BARS