tow 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 906 of 1691
mirror operation is not as specified, check for open or short circuit
between switch and power mirror. Repair as necessary. If wiring
harness is okay, replace mirror assembly as necessary. See Fig. 2.
POWER MIRROR MOTOR TEST (CARAVAN, TOWN & COUNTRY, & VOYAGER)
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Apply 12 Volts Ground Mirror Operation Mirror Operation
To Pin Pin (Right) (Left\
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Switch Connector ( 1)
12 ............. 6 ............. N/A ...................... Up
7 .............. 6 ............. N/A .................... Left
6 .............. 12 ............ N/A .................... Down
6 .............. 7 ............. N/A ................... Right
13 ............. 1 ............. Up ...................... N/A
8 .............. 1 ............ Left ..................... N/A
1 .............. 13 ........... Down ..................... N/A
1 .............. 8 ............ Right .................... N/A
5 .............. 11 ............ ( 2) ..................... ( 2)
( 1) - Use illustration for connector pin identification. See Fig. 2.
( 2) - Used for switch illumination. No mirror movement will be
observed.
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Fig. 2: Identifying Power Mirror Switch Connector Pins (Caravan,
Town & Country, & Voyager)
Courtesy of Chrysler Corp.
Dakota, Durango, Ram Pickup, Ram Van & Ram Wagon
Page 908 of 1691
Caravan, Town & Country, & Voyager
Remove switch and disconnect wiring connector. See POWER
MIRROR SWITCH under REMOVAL & INSTALLATION. Using an ohmmeter, check
continuity between power mirror switch terminals with switch in
appropriate position. See POWER MIRROR SWITCH CONTINUITY TEST
(CARAVAN, TOWN & COUNTRY, & VOYAGER) table. See Fig. 2. If results
differ from table, replace switch.
POWER MIRROR SWITCH CONTINUITY TEST (CARAVAN, TOWN & COUNTRY, &
VOYAGER)
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Mirror Selector Mirror Angle Continuity Between Pins
Position
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"L" (Left) Up 9 & 12; 6 & 11; 9 & 13
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Down 9 & 6; 12 & 11; 13 & 11
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Left 9 & 7; 6 & 11; 9 & 8
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Right 9 & 6; 7 & 11; 8 & 11
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"R" (Right) Up 9 & 13; 1 & 11; 9 & 12
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Down 9 & 1; 13 & 11; 12 & 11
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Left 9 & 8; 1 & 11; 9 & 7
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Right 9 & 1; 8 & 11; 7 & 11
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Illumination N/A 5 & 11
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Dakota, Durango, Ram Pickup, Ram Van & Ram Wagon
Remove switch and disconnect wiring connector. See POWER
MIRROR SWITCH under REMOVAL & INSTALLATION. Using an ohmmeter, check
continuity between power mirror switch terminals with switch in
appropriate position. See POWER MIRROR SWITCH CONTINUITY TEST (DAKOTA,
DURANGO, RAM PICKUP, RAM VAN & RAM WAGON) table. See Fig. 4. If
results differ from table, replace switch.
POWER MIRROR SWITCH CONTINUITY TEST (DAKOTA, DURANGO, RAM PICKUP,
RAM VAN & RAM WAGON)
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Mirror Selector Mirror Angle Continuity Between Pins
Position
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"L" (Left) Up 1 & 7; 3 & 8; 4 & 7
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Down 1 & 8; 3 & 7; 4 & 8
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Left 2 & 7; 3 & 8; 5 & 7
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Right 2 & 8; 3 & 7; 5 & 8
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"R" (Right) Up 1 & 7; 4 & 7; 6 & 8
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Down 1 & 8; 4 & 8; 6 & 7
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Left 2 & 7; 5 & 7; 6 & 8
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Page 909 of 1691
![DODGE RAM 1999 Service Manual PDF Right 2 & 8; 5 & 8; 6 & 7
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\](/img/12/56915/w960_56915-908.png "DODGE RAM 1999 Service Manual PDF Right 2 & 8; 5 & 8; 6 & 7
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Right 2 & 8; 5 & 8; 6 & 7
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Fig. 4: Identifying Power Mirror Motor Switch Connector Pins
(Dakota, Durango, Ram Pickup, Ram Van & Ram Wagon)
Courtesy of Chrysler Corp.
POWER MIRROR DEFOGGER
NOTE: On Caravan, Town & Country and Voyager, heated mirror is
controlled by rear window defogger switch. Heated mirror is
on whenever rear window defogger is on.
Caravan, Town & Country, & Voyager
1) Mirror should be warm to touch with rear window defogger
activated. If mirror is not warm to touch, check fuse No. 12 (10-amp)
in junction block. Repair short circuit and replace fuse as necessary.
Check for battery voltage at mirror harness connector Light
Blue/Yellow wire with rear window defogger switch on. If battery
voltage does not exist, repair wiring as necessary. See WIRING
DIAGRAMS. If battery voltage exists, go to next step.
Page 910 of 1691
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.
Page 911 of 1691
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.
Page 912 of 1691
WIRING DIAGRAMS
Fig. 5: Power Mirror System Wiring Diagram (Caravan, Town &
Country, & Voyager)
Page 929 of 1691
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.
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 932 of 1691
Removal
1) Raise and support vehicle. Disconnect negative battery
cables. Drain fuel tank. Remove fuel tank filler tube bolts from body.
Support fuel tank with transmission jack. Remove fuel tank straps and
heat shields (if equipped).
2) Slightly lower fuel tank for access to fuel lines and
electrical connector at fuel tank module. Disconnect electrical
connector and fuel lines at fuel tank module. See Fig. 7. Use proper
procedure when disconnecting fuel lines. See FUEL LINE DISCONNECT
FITTINGS under FUEL SYSTEM.
NOTE: Information for servicing of in-tank fuel filter is not
available from manufacturer. If necessary to service in-tank
fuel filter, consult parts department to verify if filter may
be replace without replacing fuel tank module.
3) Note direction of fuel line connections on fuel tank
module for installation reference. Using Spanner Wrench (6856),
unscrew plastic fuel tank module lock nut from fuel tank. Remove fuel
tank module and gasket from fuel tank. Inspect in-tank fuel filter for
damage.
Installation
1) Using NEW gasket, install fuel tank module in fuel tank.
Install plastic fuel tank module lock nut finger tight. DO NOT tighten
plastic fuel tank module lock nut at this time.
2) Position fuel tank module so fuel line connections and
electric connection are facing toward driver's side of vehicle. This
must be done to prevent float on fuel gauge sending unit from
contacting fuel tank.
3) Once fuel tank module is properly positioned, tighten
plastic fuel tank module lock nut to specification. See TORQUE
SPECIFICATIONS.
4) Install fuel lines on fuel tank module using proper
procedure. See FUEL LINE DISCONNECT FITTINGS under FUEL SYSTEM.
Install electrical connector on fuel tank module. Reinstall fuel tank.
Tighten fuel tank strap nuts to specification. See TORQUE
SPECIFICATIONS. Reconnect negative battery cables.
Fig. 7: Locating Fuel Tank Module & Fuel Tank Rollover Valve
Courtesy of Chrysler Corp.
FUEL INJECTOR DRAIN LINE ASSEMBLY
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.