coolant DODGE RAM 1999 Service Manual Online
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 889 of 1691
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Refrigerant A/C System Capacity 7.75 Oz. (230ML)
Oil
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Fuel Tank Capacity 35 Gal. (132L)
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1) - Capacities are recommended or calculated levels. Always use
dipstick (if available) to measure level.
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LUBRICATION SPECIFICATIONS - GAS
LUBRICATION SPECIFICATIONS TABLE - GAS \
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Material Condition Specification
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Engine Oil Ambient Temperature Above 0 \bF SAE 10W-30
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1) (-18\bC) To Over 100\bF (38\bC)
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Ambient Temperature Less Than SAE 5W-30
-20\bF (-29\bC) Up To 32\bF (0\bC)
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Engine All 50/50 Mixture Of
Coolant Distilled Water &
Ethylene Glycol
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Brake Fluid All DOT 3
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Automatic All ATF+2 Type 7176
Transmission
Fluid
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Transfer Case All ATF+2 Type 7176
Fluid Or DEXRON III ATF
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Manual NV-4500 75W-90 Synthc. API GL4
Transmission
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Fluid NV-3500 Mopar Manual
Transmission Fluid
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Steering All Mopar Multi-Mileage
Linkage Lubricant
Lubricant
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Wheel Bearing All High Temperature Multi-
Grease -Purporse EP Grease
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Rear Axle & All Mopar Hypoid Lubricant
4x4 Frt. Axle SAE 80W-90
Lubricant (
2) GL-5 Gear Lube
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Power All Mopar Power Steering
Steering Fluid Or Equivalant
Fluid (
3) Petroleum Based
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Clutch All Multipurpose Grease
Linkage NLGI Grade 2 E.P.
Lubricant
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A/C All R-134a
Page 890 of 1691
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Refrigerant
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A/C All Polyalkalene Glycol
Refrigerant SP10 PAG
Oil Refrigerant Oil
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(
1) - SAE 10W-30 engine oil is preferred for use in all Dodge
trucks. Use only API approved oil with Starburst Symbol.
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2) - Limited-Slip Differentials require the use of a 5% Friction
Modifier. Mopar Gear Oil Additive Friction Modifier
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3) - Never add gear oil, automatic transmission fluid or
hydroboost power steering fluid.
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FLUID CAPACITIES - GAS
FLUID CAPACITIES TABLE - GAS \
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Item Condition Specification (1)
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Engine Oil 3.9L: Drained, W/New Filter 4 Qts. (3.8L)
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5.2L: Drained, W/New Filter 5 Qts. (4.7L)
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5.9L: Drained, W/New Filter 5 Qts. (4.7L)
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3.9L: Drained 3.5 Qts. (3.3L)
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5.2L: Drained 4.5 Qts. (4.2L)
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5.9L: Drained 4.5 Qts. (4.2L)
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Engine 3.9L: Drained 20 Qts. (19L)
Coolant
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5.2L: Drained 20 Qts. (19L)
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5.9L: Drained 20 Qts. (19L)
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Automatic 42RE: Dry Fill 17-22 Pts. (8-10.4L)
Transmission
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Fluid 46RE: Dry Fill 1726 Pts. (812.3L)
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Manual NV3500: Drained 4.2 Pts. (2L)
Transmission
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Fluid NV3500: Drained 8 Pts. (3.8L)
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Rear Axle 9-1/4: Drained 4.8 Pts. (2.3L)
Fluid
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Model 248 (2WD) 6.3 Pts. (3L)
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Model 248 (4WD) 7.3 Pts. (3.4L)
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Model 267 (2WD) 7 Pts. (3.3L)
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Model 267 (4WD) 7.8 Pts. (3.6L)
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Model 286 (2WD) 6.8.Pts. (3.2L)
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Model 286 (4WD) 10.1 Pts. (4.8L)
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Rear Axle Model 248 (2WD) 6.3 Pts. (3L)
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
Page 924 of 1691
CAUTION: If turbocharger failure exists, intercooler must be cleaned.
See INTERCOOLER under AIR INDUCTION SYSTEMS.
Removal
1) Disconnect negative battery cables. Disconnect air inlet
tube and exhaust pipe from turbocharger. Disconnect intercooler inlet
duct from turbocharger. See Fig. 2.
2) Disconnect and plug turbocharger oil supply line and
turbocharger oil drain line at turbocharger. Remove turbocharger
retaining nuts, turbocharger and gasket from exhaust manifold. Plug
all air intake openings.
Installation
1) Apply anti-seize compound on turbocharger mounting studs.
Using NEW gasket, install turbocharger. Install and tighten
turbocharger retaining nuts to specification. See TORQUE
SPECIFICATIONS.
2) Using NEW gasket, install turbocharger oil drain line on
turbocharger. Install and tighten turbocharger oil drain line bolts to
specification. See TORQUE SPECIFICATIONS.
CAUTION: Turbocharger must be pre-lubricated by pouring clean engine
oil in turbocharger oil supply line fitting on turbocharger
before starting the engine.
WARNING: DO NOT rotate turbine wheel in turbocharger with your finger,
as sharp edges may exist.
3) Pour 3 ozs. (60 cc) of clean engine oil into turbocharger\
oil supply line fitting on turbocharger while using soft object to
rotate turbine wheel in turbocharger. This must be done to pre-
lubricate the turbocharger.
4) Install turbocharger oil supply line on turbocharger and
tighten nut to specification. See TORQUE SPECIFICATIONS. To install
remaining components, reverse removal procedure. Tighten bolts/nuts to
specification. See TORQUE SPECIFICATIONS.
TURBOCHARGER WASTEGATE ADJUSTMENT
NOTE: For turbocharger wastegate adjustment, see CONTROL ROD
ADJUSTMENT under TURBOCHARGER WASTEGATE in ON-VEHICLE
ADJUSTMENTS - DIESEL article.
ENGINE SENSORS & SWITCHES
ENGINE COOLANT TEMPERATURE SENSOR
Removal & Installation
1) Engine coolant temperature sensor is located at front of
cylinder head near thermostat. See Fig. 3.
2) Partially drain cooling system until coolant level is
below the cylinder head. Disconnect ECT sensor electrical connector.
Remove ECT sensor from cylinder head. Discard "O" ring. To install,
reverse removal procedure. Use new "O" ring.
CRANKSHAFT POSITION SENSOR (CKP)
NOTE: Crankshaft Position (CKP) sensor may be referred to as engine\
speed sensor.
Removal & Installation
1) CKP sensor is located on left rear side of engine block
Page 941 of 1691
![DODGE RAM 1999 Service Manual Online Removal & Installation
See INTAKE MANIFOLD AIR HEATER RELAYS under RELAYS &
SOLENOIDS.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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See INTAKE MANIFOLD AIR HEATER RELAYS under RELAYS &
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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Removal & Installation
See INTAKE MANIFOLD AIR HEATER RELAYS under RELAYS &
SOLENOIDS.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)\
Access Plug ................................................ 11 (15)\
AFC Line-To-Fuel Injection Pump Fitting .................... 18 (24)\
Air Inlet Housing Bolt ..................................... 18 (24)\
Engine Bracket-To-Engine Bolts ............................. 18 (24)\
Engine Coolant Temperature Sensor .......................... 40 (54)\
Engine Speed Sensor Nut .................................... 18 (24)\
Fuel Injection Pump Drive Gear Nut ....................... 125 (170)\
Fuel Injection Pump Lower Bracket-To-Pump Bolts ............ 18 (24)\
Fuel Injection Pump Mount Nuts ............................. 32 (43)\
Fuel Injector Retaining Nut ................................ 44 (60)\
Fuel Line-To-Fuel Heater Fitting ........................... 18 (24)\
Fuel Line-To-Fuel Transfer Pump ............................ 18 (24)\
Fuel Supply Line Banjo Bolt ................................ 18 (24)\
Fuel Tank Strap Nut ........................................ 30 (41)\
Fuel Transfer Pump Bolt .................................... 18 (24)\
High-Pressure Fuel Line Clamp Bolt ......................... 18 (24)\
High-Pressure Fuel Line Nut (At Injector) .................. 28 (38\
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High-Pressure Fuel Line Nut (At Pump) ...................... 18 (24\
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Intake Manifold Air Heater Housing Bolt .................... 18 (24)\
Intake Manifold Air Temperature Sensor ..................... 20 (27)\
Intake Manifold Cover Bolt ( 1) ............................. 18 (24)
Oil Fill Plug .............................................. 21 (29)\
Overflow Valve-To-Fuel Injection Pump ...................... 24 (33)\
Park/Neutral Switch ........................................ 25 (34)\
Plastic Fuel Tank Module Lock Nut .......................... 32 (43)\
Starter Mounting Bolt ...................................... 32 (43)\
Turbocharger Oil Drain Line Bolt ........................... 18 (24)\
Turbocharger Oil Supply Line Nut ........................... 11 (15)\
Turbocharger Retaining Nut ................................. 24 (33)\
INCH Lbs. (N.m)
Air Inlet Tube-To-Turbocharger Clamp Nut .................. 72 (8.1)\
Canister Nut ............................................ 120 (13.6)\
Condenser-To-Intercooler Nut ............................. 95 (10.7)\
Condenser-To-Intercooler Screw ........................... 95 (10.7)\
Drain Valve-To-Canister Bolt .............................. 40 (4.5)\
Exhaust Pipe-To-Turbocharger Clamp Nut .................... 72 (8.1)\
Fuel Bleed Bolt ........................................... 72 (8.1)\
Fuel Injector Drain Line Assembly Retaining Clamp Bolt .. 120 (13.6)\
Fuel Injector Drain Line-To-Fuel Injector Banjo Bolt ...... 84 (9.5)\
Intake Manifold Air Heater Relay Assembly Retaining Bolt .. 40 (4.5)\
Intercooler Bolt .......................................... 17 (1.9)\
Intercooler Inlet & Outlet Duct Clamp ..................... 72 (8.1)\
PCM Mounting Bolt ......................................... 35 (4.0)\
Water-In-Fuel (WIF) Sensor ................................ 20 (2.3\
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( 1) - Apply thread sealant to bolt threads.
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Page 946 of 1691
Removal
Downstream oxygen sensor is mounted on exhaust pipe, behind
catalytic converter. Raise and support vehicle. Disconnect electrical
connector for downstream oxygen sensor. Using Socket (YA8875), remove
downstream oxygen sensor from exhaust pipe.
Installation
If installing original or used downstream oxygen sensor,
apply anti-seize compound on threads of downstream oxygen sensor. A
NEW downstream oxygen sensor should already be coated with anti-seize
compound. Install and tighten downstream oxygen sensor to
specification. See TORQUE SPECIFICATIONS. Install electrical
connector.
ENGINE COOLANT TEMPERATURE SENSOR
Removal & Installation (Dakota 2.5L)
1) Partially drain cooling system. Disconnect electrical
connector at engine coolant temperature sensor. Engine coolant
temperature sensor is located on side of thermostat housing and
contains a Tan/Black wire and a Black/Light Blue wire in the
electrical connector.
2) Remove engine coolant temperature sensor. To install,
reverse removal procedure. Tighten engine coolant temperature sensor
to specification. See TORQUE SPECIFICATIONS. Fill cooling system.
Removal (Dakota 3.9L, 5.2L & 5.9L, Durango & Ram Pickup 3.9L,
5.2L & 5.9L)
1) Partially drain cooling system. Engine coolant temperature
sensor is located on front of intake manifold, near inside of
generator and contains a Tan/Black wire and a Black/Light Blue wire in
the electrical connector.
2) Remove air cleaner if necessary for access to engine
coolant temperature sensor. On models equipped with A/C, go to next
step. On models not equipped with A/C, disconnect electrical connector
at engine coolant temperature sensor. Remove engine coolant
temperature sensor.
3) On A/C equipped models, electrical connector on engine
coolant temperature sensor may be difficult to reach. It may be
necessary to use a coat hanger and fabricate an "L" shaped tool about
8" (203 mm) long to disconnect electrical connector by placing hook
part of tool under electrical connector and pulling electrical
connector upward from engine coolant temperature sensor. Remove engine
coolant temperature sensor.
Installation
To install, reverse removal procedure. Tighten engine coolant
temperature sensor to specification. See TORQUE SPECIFICATIONS. Fill
cooling system.
Removal & Installation (Ram Pickup 8.0L)
1) Partially drain cooling system. Engine coolant temperature
sensor is located on front of intake manifold, near rear of generator
and contains a Tan/Black wire and a Black/Light Blue wire in the
electrical connector.
2) Disconnect electrical connector at engine coolant
temperature sensor. Remove engine coolant temperature sensor.
3) To install, reverse removal procedure. Tighten engine
coolant temperature sensor to specification. See TORQUE
SPECIFICATIONS. Fill cooling system.
Removal (Ram Van & Ram Wagon)
Page 947 of 1691
1) Partially drain cooling system. Engine coolant temperature
sensor is located on front of intake manifold, near inside of
generator and contains a Tan/Black wire and a Black/Light Blue wire in
the electrical connector.
2) On 3.9L, remove engine cover and air cleaner housing from
inside of vehicle for access to engine coolant temperature sensor. On
5.2L and 5.9L, engine coolant temperature sensor may be serviced from
front of vehicle without removing engine cover and air cleaner
housing.
3) On all models, disconnect electrical connector at engine
coolant temperature sensor. It may be necessary to use a coat hanger
and fabricate an "L" shaped tool about 8" (203 mm) long to disconnect
electrical connector by placing hook part of tool under electrical
connector and pulling electrical connector upward from engine coolant
temperature sensor. Remove engine coolant temperature sensor.
Installation
To install, reverse removal procedure. Tighten engine coolant
temperature sensor to specification. See TORQUE SPECIFICATIONS. Fill
cooling system.
FUEL LEVEL SENSOR
Removal & Installation
See FUEL LEVEL SENSOR under FUEL SYSTEM.
INTAKE AIR TEMPERATURE (IAT) SENSOR
NOTE: Intake air temperature sensor may also be referred to as
intake manifold air temperature sensor.
Removal & Installation (Dakota, Durango & Ram Pickup)
1) IAT sensor is screwed into the intake manifold. See Fig. 4
, 5 or 6. Remove air inlet duct or air cleaner assembly for access to
IAT sensor if necessary. Disconnect electrical connector at IAT
sensor. Remove IAT sensor from intake manifold.
2) To install, reverse removal procedure. Tighten IAT sensor
to specification. See TORQUE SPECIFICATIONS.
Removal & Installation (Ram Van & Ram Wagon)
1) IAT sensor is screwed into the intake manifold. See Fig. 5
. On 3.9L, remove engine cover and air cleaner housing from inside of
vehicle for access to IAT sensor. On 5.2L and 5.9L, IAT sensor may be
serviced from front of vehicle without removing engine cover and air
cleaner housing.
2) On all models, disconnect electrical connector at IAT
sensor. Remove IAT sensor from intake manifold. To install, reverse
removal procedure. Tighten IAT sensor to specification. See TORQUE
SPECIFICATIONS.
Fig. 4: Locating Intake Air Temperature (IAT) Sensor (Dakota 2.5L)
Courtesy of Chrysler Corp.
Page 997 of 1691
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Application Ft. Lbs. (N.m)\
Crankshaft Position Sensor Bolt
2.5L ..................................................... 14 (19)\
3.9L, 5.2L & 5.9L ............................................ (1)
8.0L ......................................................... ( 1)
Downstream Oxygen Sensor ................................... 22 (30)\
Distributor Hold-Down Bolt ................................. 17 (23)\
EVAP Canister-To-Mounting Bracket Nut
Dakota & Durango ......................................... 17 (23)\
Ram Pickup ................................................... ( 2)
Ram Van & Ram Wagon .......................................... ( 3)
Fuel Pump Module Lock Nut
Dakota ................................................... 40 (54)\
Ram Pickup ............................................... 32 (43)\
Ram Van & Ram Wagon ...................................... 40 (54)\
Fuel Rail Bolt
2.5L ......................................................... ( 4)
3.9L, 5.2L & 5.9L ........................................ 17 (23)\
8.0L ..................................................... 11 (15)\
Fuel Tank Strap Nut
Dakota & Durango ......................................... 40 (54)\
Ram Pickup ............................................... 30 (41)\
Ram Van & Ram Wagon .......................................... ( 5)
IAT Sensor ................................................. 20 (27)\
Park/Neutral Switch ........................................ 25 (34)\
Power Steering Pressure Switch (2.5L) ...................... 16 (22\
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Spark Plug ................................................. 30 (41)\
Throttle Body Bolt
2.5L ......................................................... ( 4)
3.9L, 5.2L & 5.9L ........................................ 17 (23)\
Throttle Body Nut (8.0L) ................................... 16 (22\
)
Upper Intake Manifold Bolt (8.0L) ...................... ( 6) 16 (22)
Upstream Oxygen Sensor ..................................... 22 (30)\
Wheel Lug Nut (Dakota & Durango) ......................... 100 (136\
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INCH Lbs. (N.m)
Air Cleaner Housing-To-Throttle
Body Nut (Dakota & Durango) ............................. 96 (10.8\
)
Camshaft Position Sensor Bolt (8.0L) ...................... 50 (5.6\
)
Engine Coolant Temperature Sensor ........................ 96 (10.8)\
EVAP Canister Mounting Bracket-To
Body Nut (Ram Van & Ram Wagon) .......................... 95 (10.7\
)
EVAP Leak Detection Pump Filter
Bolt (Ram Pickup, Ram Van & Ram Wagon) ................... 65 (7.3\
)
EVAP Leak Detection Pump Bolt ............................. 11 (1.2)\
EVAP Purge Solenoid Nut (Dakota & Durango) ................ 75 (8.5\
)
IAC Motor Bolt ............................................ 60 (6.8)\
Ignition Coil Bolt/Nut
Dakota, Durango, Ram Van & Ram Wagon ......................... ( 7)
Ram Pickup
3.9L, 5.2L & 5.9L ........................................... ( 7)
8.0L .................................................. 90 (10.2)\
MAP Sensor Bolt
Dakota & Durango ........................................ 25 (2.8)\
Ram Pickup
3.9L, 5.2L & 5.9L ...................................... 25 (2.8)\
8.0L ................................................... 20 (2.3)\
Ram Van & Ram Wagon ..................................... 25 (2.8)\
PCM Bolt .................................................. 35 (4.0)\
TP Sensor Bolt ............................................ 60 (6.8)\
Page 999 of 1691
SCHEDULED SERVICES - NORMAL SERVICE (DIESEL)
1999 D odge P ic ku p R 1500
1997-99 MAINTENANCE
Chrysler Maintenance & Service Intervals
Diesel Engines
Normal Service
DODGE; RAM PICKUP Cummins Turbo Diesel: 5.9L VIN [D]
* READ THIS FIRST *
Before preforming maintenance on vehicle, ensure that all
cautions and warnings have been observed to prevent vehicle damage or
personal injury. See CAUTIONS & WARNINGS in MAINTENANCE INFORMATION
article in this section.
Introduction
The frequency of scheduled inspection and maintenance
services in this article are based on normal vehicle usage ONLY. The
following Severe conditions are NOT taken into account:
* Frequent short driving less than 5 Miles (8 Km).
* Frequent driving in dusty conditions.
* Frequent trailer towing.
* Extensive idling.
* More than 50% of your driving is at sustained high speeds
during hot weather, above 90
F (32 C).
If the vehicle is operated mainly under any of these
conditions, this Normal service schedule article is inadequate. DO NOT
USE. Instead, use the Severe service schedule: See
SCHEDULED SERVICES - NORMAL SERVICE (DIESEL) .
6,000 MILE (10,000 KM)/6 MONTH NORMAL SERVICE
6,000 MILE (10,000 KM)/6 MONTH NORMAL SERVICE\
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Exhaust System
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Engine Coolant Level, Hoses & Clamps
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SERVICE
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REPLACE
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Page 1000 of 1691
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Engine Oil Ambient Temperature Above 10 F SAE 15W-40
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Ambient Temperature Less Than SAE 10W-30
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Ambient Temperature Less Than With Block Heater:
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Without Block Heater:
SAE 5W-30
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Engine All 50/50 Mixture Of
Coolant Distilled Water &
Ethylene Glycol
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Brake Fluid All DOT 3
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Steering All Mopar Multi-Mileage
Linkage Lubricant
Lubricant
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(
1) - SAE 10W-30 engine oil is preferred for use in all Dodge
trucks. 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 Capacity, Upper Safe Mark 10 Qts. (9.5L)
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Capacity, Lower Safe Mark 8 Qts. (7.5L)
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Engine Drained 26 Qts. (24.5L)
Coolant
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(
1) - Capacities are recommended or calculated levels. Always use
dipstick (if available) to measure level.
\f
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12,000 MILE (19,000 KM)/12 MONTH NORMAL SERVICE
12,000 MILE (19,000 KM)/12 NORMAL 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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Water Pump Weep Hole For Blockage
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SERVICE
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Rotate Tires
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Lubricate Steering Linkage
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Clean Fuel Strainer
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REPLACE