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
Page 919 of 1691
Normal Maximum Time-Out
Component Draw Draw (Minutes)
Anti-Theft System ................ 0.4 .... 1.0 ....... ...
Auto Door Lock ................... 1.0 .... 1.0 ....... ...
Body Control Module .............. 3.6 ... 12.4 ........ 20
Central Processing System ........ 1.6 .... 2.7 ........ 20
Electronic Control Module ........ 5.6 ... 10.0 ....... ...
Electronic Level Control ......... 2.0 .... 3.3 ........ 20
Heated Windshield Module ......... 0.3 .... 0.4 ....... ...
HVAC Power Module ................ 1.0 .... 1.0 ....... ...
Illuminated Entry ................ 1.0 .... 1.0 ......... 1
Light Control Module ............. 0.5 .... 1.0 ....... ...
Oil Level Module ................. 0.1 .... 0.1 ....... ...
Multi-Function Chime ............. 1.0 .... 1.0 ....... ...
Pass Key Decoder Module ......... 0.75 .... 1.0 ....... ...
Power Control Module ............. 5.0 .... 7.0 ....... ...
Retained Accessory Power ......... 3.8 .... 3.8 ....... ...
Radio ............................ 7.0 .... 8.0 ........ 15
Twilight Sentinel Module ......... 1.0 .... 1.0 ....... ...
Voltage Regulator ................ 1.4 .... 2.0 ....... ...
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INTERMITTENT PARASITIC LOAD PROBLEMS
Intermittent parasitic lad can occur because of a memory
device that does not power down with ignition off. With an
intermittent parasitic load, battery draw can be greater than 1.0 amp.
To find and intermittent problem requires that an ammeter and
Disconnect Tool (J-38758) test switch be connected and left in the
circuit. See Fig. 1. Road test vehicle. After road test, turn ignition
off and remove key.
Monitor the milliamps scale for 15-20 minutes after ignition
is turned off. This allows monitoring memory devices to determine if
they time out and stop drawing memory current. The test switch is
needed to protect ammeter when the vehicles is started.
DIODE CHECK & SOLENOID TEST (GENERAL MOTORS)
Page 930 of 1691
FUEL LINE BLEEDING
NOTE: Fuel line bleeding is necessary if fuel injection pump is
replaced, fuel filter/water separator is not filled with
diesel fuel before installing or vehicle ran out off fuel.
Bleed high-pressure fuel lines if connections are loosened or
replaced. If engine has not been operated for an extended
time, bleed fuel lines before next initial engine start-up.
WARNING: DO NOT bleed fuel lines on a hot engine, as high exhaust
temperatures may cause a fire. Carefully bleed fuel lines, as
fuel is under extremely high pressure and could penetrate
skin. Use safety goggles and protective clothing when
bleeding fuel lines.
1) Loosen banjo bolt holding low-pressure fuel supply line to
side of fuel injection pump. Wrap a towel around banjo fitting to
catch fuel. Crank engine quickly and release key before engine starts.
This will operate fuel transfer pump for about 25 seconds.
2) If fuel is not present at fuel supply line after 25
seconds, turn ignition off. Repeat engine crank procedure until fuel
is present at fuel supply line. Tighten banjo bolt at fuel supply line
to specification. See TORQUE SPECIFICATIONS.
CAUTION: Ensure parking brake is applied and transmission is in
Neutral before bleeding fuel injection pump or high-pressure
fuel lines. DO NOT operate starter for more than 30 seconds
when bleeding fuel injection pump or high-pressure fuel
lines. Allow 2-minute intervals between starter operations.
3) To bleed air from fuel injection pump, ensure parking
brake is applied and transmission is in Neutral, as engine may start
when operating starter to bleed air from fuel injection pump. Operate
starter for 30 seconds to bleed any trapped air in fuel injection
pump.
4) To bleed high-pressure fuel lines, ensure parking brake is
applied and transmission is in Neutral, as engine may start when
operating starter to bleed high-pressure fuel lines. Loosen high-
pressure fuel line nut at fuel injector.
5) Operate starter until steady fuel flow exists at high-
pressure fuel line. Tighten high-pressure fuel line nut to
specification. See TORQUE SPECIFICATIONS. Start engine. Repeat
procedure on each high-pressure fuel line until engine operates
smoothly.
FUEL FILTER/WATER SEPARATOR & WATER-IN-FUEL SENSOR
NOTE: Vehicle also contains an in-tank fuel filter located on
bottom of fuel tank module. For servicing procedure, see FUEL
TANK MODULE & IN-TANK FUEL FILTER under FUEL SYSTEM.
NOTE: When fuel filter/water separator is being replaced,
manufacturer recommends cleaning the pre-filter. See FUEL
HEATER under FUEL SYSTEM for servicing of pre-filter.
Removal
1) Ensure engine is off. Place drain pan below drain tube at
fuel filter/water separator. See Fig. 3. Rotate handle on drain valve
forward, toward front of vehicle to DRAIN position. Drain valve is
located near top of fuel filter/water separator. See Fig. 3. Once fuel
is drained from fuel filter/water separator, rotate handle on drain
valve back to CLOSE position.
Page 934 of 1691
Apply light coat of engine oil on NEW .060" (1.5 mm) thick Copper
sealing washer. Install NEW Copper sealing washer on spray tip of fuel
injector. Engine oil is used to aid holding sealing washer in place.
Install new "O" ring on fuel injector. Apply small amount of engine
oil to "O" ring.
2) Ensure fuel inlet hole on side of fuel injector is
positioned toward injector connector tube. Install injector into
cylinder head bore using care not to allow injector tip to touch sides
of bore. Press fuel injector into cylinder head with finger pressure
only. Install fuel injector hold down clamp into shouldered bolt while
aligning slot in top of injector into groove in bottom of clamp.
Tighten opposite clamp bolt to specification. See TORQUE
SPECIFICATIONS.
3) Apply small amount of clean engine oil to NEW "O" ring.
Install "O" ring to fuel injector connector tube. Using finger
pressure only, press injector connector tube into cylinder head.
Connect and tighten high pressure fuel lines to specification. See
TORQUE SPECIFICATIONS.
NOTE: Fuel line fitting torque is important. Mating surfaces will
not seal if fuel line fitting is under or over-torqued.
4) To install remaining components, reverse removal
procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Bleed high-pressure fuel lines. See FUEL LINE BLEEDING under FUEL
SYSTEM.
FUEL INJECTION PUMP
CAUTION: High-pressure fuel lines must be clamped securely and routed
so they do not contact each other or any other components. DO
NOT weld or substitute high-pressure fuel lines. High
-pressure lines are same length and proper high-pressure fuel
line must be installed in specified area for proper engine
operation.
Removal
1) Disconnect negative battery cables. Clean fuel lines at
cylinder head and injection pump. Clean fuel injection pump and fuel
lines at side of pump. Disconnect 9-pin electrical connector at Fuel
Pump Control Module (FPCM). Place a rag around overflow valve to catch\
excess fuel. Remove overflow valve and disconnect fuel return line.
Remove banjo bolts and fuel supply line at side of injection pump and
top of fuel filter housing.
2) Remove all high pressure fuel lines, intake air tube,
accelerator pedal position sensor, air intake housing, engine oil
dipstick tube, wiring clips, electrical connectors at intake heaters,
and engine lifting bracket. Unscrew plastic access cap at front gear
cover. Remove injection pump gear-to-injection pump shaft nut and
washer.
3) Engine may be rotated by removing dust plug from
transmission adapter plate and installing Engine Barring Tool (Snap-On
SP371) in transmission adapter plate. See Fig. 9. Rotate engine until
keyway is at 12 o'clock position.
Page 935 of 1691
Fig. 9: Rotating Engine
Courtesy of Chrysler Corp.
CAUTION: Engine must be rotated until keyway is at 12 o'clock position
to prevent pump/gear keyway from falling into gear housing.
If gear retainer nut, washer or key drops into gear housing,
cover may have to be removed to retrieve them before engine
start.
4) Using gear puller, separate injection pump gear from
injection pump shaft. See Fig. 11. DO NOT pull fuel injection pump
drive gear too far forward or timing gear cover may be damaged.
5) Remove 3 lower fuel injection pump-to-lower mounting
bracket bolts. Loosen 2 engine bracket bolts. See Fig. 10. Remove 4
fuel injection pump-to-gear housing nuts. Remove fuel injection pump.
Use care not to scratch or damage shaft of fuel injection pump during
removal.
Page 937 of 1691
injection pump timing, cylinder No. 1 at TDC on compression
stroke and timing pin is engaged in machined hole on camshaft
gear.
Installation
1) Check pump mounting surfaces at pump and mounting flange
for nicks, cuts or damage. Check "O" ring surfaces for nicks, cuts or
damage. Clean injection pump mounting flange at gear housing. Clean
front of injection pump. Install new "O" ring on pump mounting area.
Apply clean engine oil to injection pump "O" ring only.
CAUTION: Ensure fuel injection pump drive gear-to-shaft mating
surfaces are clean and free of oil to provide proper seating
of fuel injection pump drive gear on shaft of fuel injection
pump.
2) Pump/gear keyway has an arrow and 3-digit number stamped
at top edge. See Fig. 12. Position keyway into pump shaft with arrow
pointed toward rear of pump. Ensure 3-digit number stamped on top of
keyway is identical as 3-digit number stamped on injection pump data
plate. If incorrect keyway is installed, a Diagnostic Trouble Code
(DTC) may be set.
Fig. 12: Locating Keyway Arrow & Keyway Number
Courtesy of Chrysler Corp.
3) Position pump assembly to mounting flange on gear cover
while aligning injection pump shaft through back of injection pump
Page 942 of 1691
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\
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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.
Page 944 of 1691
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
Page 1152 of 1691
![DODGE RAM 1999 Service Manual PDF \
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1) - SAE 10W-30 engine oil is preferred.")
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1) - SAE 10W-30 engine oil is preferred. Use only API approved
oil with Starburst Symbol.
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FLUID CAPACITIES
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Item Condition Specification (1)
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Engine Oil 5.9L: Drained, W/New Filter 5 Qts. (4.7L)
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8.0L: Drained, W/New Filter 5 Qts. (4.7L)
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5.9L: Drained 4.5 Qts. (4.2L)
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Engine 5.9L: Drained 20 Qts. (19L)
Coolant
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8.0L: Drained 24 Qts. (22.7L)
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1) - Capacities are recommended or calculated levels. Always use
dipstick (if available) to measure level.
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82,500 MILE (132,000 KM)/82 MONTH NORMAL SERVICE
82,500 MILE (132,000 KM)/82 MONTH NORMAL SERVICE\
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VERIFY
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Last Major Service Was Performed.
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REPLACE
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Oxygen Sensor (5.9L Only) (
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1) Requires service reminder indicator light. If so equipped,
these parts are to be replaced at the indicated mileage
when the service reminder indicator light remains on
continuosly with the key in the "ON" position, which occurs
first.
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84,000 MILE (134,000 KM) SEVERE DUTY SERVICE
84,000 MILE (134,000 KM) SEVERE DUTY SERVICE\
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INSPECT
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Exhaust System
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Brake Hoses
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Engine Coolant Level, Hoses & Clamps
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Engine Air Cleaner & Air Pump Filters
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Brake Linings
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SERVICE
Page 1228 of 1691
WARNING: Wait about 2 minutes after disconnecting negative battery
cable before servicing air bag system. System reserve
capacitor maintains air bag system voltage for about 2
minutes after battery is disconnected. Servicing air bag
system before 2 minutes may cause accidental air bag
deployment and possible personal injury.
REMOVAL & INSTALLATION
WARNING: All models are equipped with Air Bag Restraint System (ABRS).
See AIR BAG PRECAUTIONS before working on vehicle. Use
caution when working around steering column (air bag could
deploy).
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.
HORN PAD & STEERING WHEEL
Removal & Installation
1) Disable air bag system. See AIR BAG DISABLING. Ensure
steering wheel is in straight-ahead position. Remove nuts mounting air
bag module to steering wheel. Remove screws securing cruise control
switch to steering wheel (if equipped).
2) Disconnect wiring connectors. Remove air bag module and
cruise control switch assembly. Pry trim covers from back of steering
wheel and remove horn switch mounting screws. Disconnect horn wires.
Remove horn switch.
3) Remove steering wheel retaining nut. Reference mark
steering wheel and steering shaft. Using puller, remove steering
wheel. To install, reverse removal procedure. Align marks made during
removal. Tighten steering wheel retaining nut to specification.
STEERING COLUMN
Removal & Installation
1) Position front wheels straight ahead. Disconnect and
isolate negative battery cable. On column shift models, remove link
rod from bushing in shift lever. Discard bushing. On all models,
remove steering wheel using Puller (C-3428-B). See HORN PAD & STEERING\
WHEEL.
2) Remove steering column shaft-to-coupler retaining pin.
Push upper coupler shaft down into lower steering coupler. Remove dash
panel column cover. On column shift models, disconnect shift indicator
cable.
3) On all models, remove tilt lever (if equipped). Remove
upper and lower shroud. Remove lower fixed shroud. Disconnect
multifunction switch harness connector. Disconnect harness connectors
from ignition switch, key-in light, horn and cruise control (if
equipped).
4) Loosen upper support bracket nuts and allow column to drop
slightly. Remove upper fixed shroud. Disconnect wiring harness
retainers from column, and move harness to one side. Remove lower dash
panel. Remove lower steering column nuts. Remove column.
CAUTION: DO NOT reuse bushing in shift rod lever once shift rod is
removed. Always install a NEW bushing.
5) To install column, reverse removal procedure. Connect
Page 1232 of 1691
relay terminal No. 86 and ground to relay terminal No. 85. Continuity
should exist between terminals No. 30 and 87. Continuity should not
exist between relay terminals No. 87A and 30. If continuity is not as
specified, replace relay. If continuity is as specified, relay is
okay. Go to HORN RELAY CIRCUIT test under SYSTEM TESTS.
Fig. 1: Identifying Horn Relay Terminals
Courtesy of Chrysler Corp.
IGNITION SWITCH
NOTE: For ignition switch circuit identification, see IGNITION
SWITCH CIRCUIT FUNCTIONS table.
Remove ignition switch. See IGNITION SWITCH under REMOVAL &
INSTALLATION. Check continuity between appropriate ignition switch
terminals with switch in specified position. See IGNITION SWITCH
CONTINUITY table. See Fig. 2.
IGNITION SWITCH CONTINUITY
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Switch Position Continuity Between Terminals
ACC .......................................................... 6 & 7
OFF ............................................................ ( 1)
RUN ............................................ 2 & 7; 4 & 5; 6 & 7
START ............................................. ( 2) 1 & 7; 2 & 7
( 1) - Continuity should not exist between any terminals with key
removed.
( 2) - Continuity should also exist between terminal No. 3 and case