DODGE RAM 1999 Service Repair Manual

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\
)
High-Pressure Fuel Line Nut (At Pump) ...................... 18 (24\
)
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\
)
( 1) - Apply thread sealant to bolt threads.









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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\
.
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.

Fig. 2: Locating PCM (Ram Pickup)
Courtesy of Chrysler Corp.
Fig. 3: Locating PCM (Ram Van & Ram Wagon)
Courtesy of Chrysler Corp.
PCM PROGRAMMING

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

bracket. Ensure alignment tab on brake switch aligns with opening on
mounting bracket.
CAUTION: When adjusting brake switch, DO NOT pull brake pedal back
toward brake switch with excessive pressure, or brake switch
may be damaged.
3) When brake switch is fully installed in mounting bracket,
rotate brake switch clockwise approximately 30 degrees. To ensure
proper brake switch adjustment, gently pull brake pedal back toward
brake switch as far as possible. DO NOT apply excessive pressure on
brake pedal and brake switch.
Removal (Ram Van & Ram Wagon)
1) Brake switch is located near top of brake pedal. Remove
lower steering column cover. Remove data link connector, hood release
lever and parking brake lever from lower instrument panel cover.
2) Remove lower instrument panel cover for access to brake
switch. Depress and hold brake pedal downward. Rotate brake switch
counterclockwise approximately 1/16 turn to so locking collar on brake
switch aligns with opening on mounting bracket. Pull brake switch
rearward from mounting bracket. Disconnect electrical connector from
brake switch.
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
bracket. Ensure locking collar on brake switch aligns with opening on
mounting bracket.
CAUTION: When adjusting brake switch, DO NOT pull brake pedal back
toward brake switch with excessive pressure, or brake switch
may be damaged.
3) When brake switch is fully installed in mounting bracket,
rotate brake switch clockwise approximately 1/16 turn. To ensure
proper brake switch adjustment, gently pull brake pedal back toward
brake switch as far as possible. DO NOT apply excessive pressure on
brake pedal and brake switch.
CAMSHAFT POSITION SENSOR
Removal & Installation
See CAMSHAFT POSITION SENSOR under IGNITION SYSTEM.
CRANKSHAFT POSITION SENSOR
Removal & Installation
See CRANKSHAFT POSITION SENSOR under IGNITION SYSTEM.
DOWNSTREAM OXYGEN SENSOR
NOTE: Downstream oxygen sensor may also be referred to as post
-catalyst oxygen sensor.

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)

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.

Fig. 5: Locating Intake Air Temperature (IAT) 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. 6: Locating Intake Air Temperature (IAT) Sensor (Ram Pickup
8.0L)
Courtesy of Chrysler Corp.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

Removal & Installation (Dakota, Durango & Ram Pickup 2.5L,
3.9L, 5.2L & 5.9L)
1) MAP sensor is located near throttle body and contains a 3-
pin electrical connector with an L-shaped rubber hose connecting it to
the throttle body. See Fig. 7 or 8. Remove air inlet duct or air
cleaner assembly for access to MAP sensor if necessary.
2) Ensure area around MAP sensor is clean. Disconnect
electrical connector at MAP sensor. Remove MAP sensor retaining bolts.
Remove MAP sensor while disconnecting L-shaped rubber hose from
throttle body. Remove L-shaped rubber hose from MAP sensor.
3) To install, reverse removal procedure. Ensure L-shaped
rubber hose is properly installed on throttle body and MAP sensor.
Tighten MAP sensor retaining bolts to specification. See TORQUE
SPECIFICATIONS.
Removal & Installation (Ram Pickup 8.0L)
1) MAP sensor is located on upper side of intake manifold and
contains a 3-pin electrical connector. See Fig. 9. Disconnect
electrical connector at MAP sensor.
2) Ensure area around MAP sensor is clean. Remove MAP sensor
retaining bolts. Remove MAP sensor with rubber seal gasket from intake
manifold. Rubber seal gasket is part of the MAP sensor and is not
serviceable. Inspect rubber seal gasket for damage. Replace MAP sensor
with rubber seal gasket if gasket is defective.
3) To install, reverse removal procedure. Ensure seal area in
upper intake manifold is clean before installing MAP sensor. Lubricate
rubber seal gasket with engine oil before installing MAP sensor.
Tighten MAP sensor retaining bolts to specification. See TORQUE
SPECIFICATIONS.
Removal & Installation (Ram Van & Ram Wagon)
1) MAP sensor is located near throttle body and contains a 3-
pin electrical connector with an L-shaped rubber hose connecting it to
the throttle body. See Fig. 8. Remove engine cover and air cleaner
assembly for access to MAP sensor if necessary.
2) Ensure area around MAP sensor is clean. Disconnect
electrical connector at MAP sensor. Remove MAP sensor retaining bolts.
Remove MAP sensor while disconnecting L-shaped rubber hose from
throttle body. Remove L-shaped rubber hose from MAP sensor.
3) To install, reverse removal procedure. Ensure L-shaped
rubber hose is properly installed on throttle body and MAP sensor.
Tighten MAP sensor retaining bolts to specification. See TORQUE
SPECIFICATIONS.
Fig. 7: Locating Manifold Absolute Pressure (MAP) Sensor (Dakota
2.5L)
Courtesy of Chrysler Corp.

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