Fuel pressure DODGE RAM 1999 Service Repair Manual

"B" ABBREVIATION TABLE

"B" ABBREVIATION TABLE
ABBREVIATION DEFINITION B/P Backpressure BAC By-Pass Air Control BAP Barometric Absolute Pressure Sensor BARO Barometric BBDC Before Bottom Dead Center BCM Body Control Module BDC Bottom Dead Center BHP Brake Horsepower BLK Black BLU Blue BMAP Barometric & Manifold Absolute Pressure
Sensor BOO Brake On-Off Switch BP Barometric Pressure sensor BPS Barometric Pressure sensor BPT Backpressure Transducer BRN Brown BTDC Before Top Dead Center BTU British Thermal Unit BVSV Bimetallic Switching Valve Baro. Barometric Batt. Battery Bbl. Barrel (Example:4-Bbl.) Blst. Ballast Blwr. Blower Brkr. Breaker

"C" ABBREVIATION TABLE

"C" ABBREVIATION TABLE
ABBREVIATION DEFINITION C Celsius (Degrees) C(3) Computer Controlled Coil Ignition C(4) Computer Controlled Catalytic Converter CANP Canister Purge solenoid CARB California Air Resources Board CAT Catalytic Converter CB Circuit Breaker CBD Closed Bowl Distributor CBVV Carburetor Bowl Vent valve cc Cubic Centimeter CCC Computer Command Control CCD Computer Controlled Dwell CCM Central Control Module CCO Converter Clutch Override CCOT Cycling Clutch Orifice Tube CCW Counterclockwise CDI Capacitor Discharge Ignition CEC Computerized Engine Control CFI Central Fuel Injection CID Cubic Inch Displacement CID Cylinder Identification sensor CIS Continuous Injection System CIS-E Continuous Injection System-Electronic

"E" ABBREVIATION TABLE

“E” ABBREVIATION TABLE
ABBREVIATION DEFINITION EAC Electric Assist Choke _ EACV Electric Air Control Valve _ EBCM Electronic Brake Control Module ECA Electronic Control Assembly ECAT Electronically Controlled Automatic
Transaxle ECM Electronic Control Module ECT Engine Coolant Temperature Sensor ECU Electronic Control Unit or Engine Control
Unit EDF Electric Drive Fan relay assembly EDIS Electronic Distributorless Ignition System EEC Electronic Engine Control EECS Evaporative Emission Control System EEPROM Electronically Erasable PROM EFE Early Fuel Evaporation _ EFI Electronic Fuel Injection _ EGO Exhaust Gas Oxygen sensor (see HEGO) EGR Exhaust Gas Recirculation system _ EGRC EGR Control solenoid or system _ EGRV EGR Vent solenoid or system _ EMR Emission Maintenance Reminder Module ESA Electronic Spark Advance _ ESC Electronic Spark Control _ EST Electronic Spark Timing _ ETR Emergency Tensioning Retractor _ EVAP Fuel Evaporative System _ EVIC Electronic Vehicle Information Center EVO Electronic Variable Orifice _ EVP EGR Valve Position Sensor _ EVR EGR Valve Regulator _ EVRV Electronic Vacuum Regulator Valve Elect. Electronic _ Eng. Engine _ Evap. Evaporative _ Exc. Except _

"F" ABBREVIATION TABLE

"F" ABBREVIATION TABLE
ABBREVIATION DEFINITION F Fahrenheit (Degrees) F/B Fuse Block FBC Feedback Carburetor FI Fuel Injector or Fuel Injection FICD Fast Idle Control Device FIPL Fuel Injector Pump Lever FP Fuel Pump FPM Fuel Pump Monitor FPR-VSV Fuel Pressure Regulator Vacuum Switching
Valve FWD Front Wheel Drive Fed. Federal Ft. Lbs. Foot Pounds

"M" ABBREVIATION TABLE

"M" ABBREVIATION TABLE
ABBREVIATION DEFINITION mA Milliamps mV Millivolts mfd. Microfarads Mm Millimeters M/T Manual Transaxle or Transmission MA PFI Mass MA or MAF Mass Airflow MAF Mass Air Flow Sensor MAFS Mass Airflow System MAP Manifold Absolute Pressure Sensor MAT Manifold Air Temperature MCU Microprocessor Control Unit MCV Mixture Control Valve MEM-CAL Memory Calibration Chip MFI Multiport Fuel Injection MIL Malfunction Incicator Light MLP Manual Lever Position MPFI Multi Point Fuel Injection MPH Miles Per Hour MPI Multi-Point (Fuel ) Injection Man. Manual Mech. Mechanical Mem. Memory Mtr. Motor

"N" ABBREVIATION TABLE

"N" ABBREVIATION TABLE
ABBREVIATION DEFINITION N.m Newton-Meter NA Not Available NDS Neutral Drive Switch NGS Neutral gear Switch NOx Oxides of Nitrogen NPS Neutral Pressure Switch No. Number Nos. Numbers

"O" ABBREVIATION TABLE

"O" ABBREVIATION TABLE
ABBREVIATION DEFINITION O Oxygen O.D. Outside Diameter O/S Oversize O2 Oxygen OC Oxidation Catalyst OCC Output Circuit Check OD Overdrive ODO Odometer

“O” ABBREVIATION TABLE (con’t) ABBREVIATION DEFINITION OHC Overhead Camshaft ORG Orange OSC Output State Check Opt. Option or Optional oz. Ounce ozs. Ounces

"P" ABBREVIATION TABLE

"P" ABBREVIATION TABLE
ABBREVIATION DEFINITION P Park P/C Printed Circuit P/N Park/Neutral P/S Power Steering PAV Pulse Air Valve PC-SOL Purge Control Solenoid PCM Powertrain Control module PCS Purge Control Solenoid PCSDM Passenger Compartment Sensor/Diagnostic Module PCV Positive Crankcase Ventilation PFE Pressure Feedback EGR sensor or circuit PFI Port Fuel Injection (see MA SEFI) PGM-CARB Programmed Carburetor PGM-FI Programmed Fuel Injection PIP Profile Ignition Pickup PNK Pink PPL Purple PRNDL Park Reverse Neutral Drive Low PROM Programmable Read-Only Memory psi Pounds Per Square Inch PSPS Power Steering Pressure Switch PTC Positive Temperature Coefficient PTO Power Take-Off PWR GND Power Ground circuit Pkg. Package Press. Pressure Prog. Programmed or Programmable Pts. Pints Pwr. Power

"Q" ABBREVIATION TABLE
"Q" ABBREVIATION TABLE
ABBREVIATION DEFINITION Qts.
Quarts

step.
7) Turn engine off. Drain transmission fluid and remove oil
pan. Inspect oil pan for burnt oil and debris. Repair transmission as
necessary. See appropriate AUTOMATIC TRANSMISSION OVERHAUL article. If
transmission is okay, no problem is found at this time, see INACTIVE
DTC CONDITION under SELF-DIAGNOSTIC SYSTEM. Testing is complete.
8) Leave gauges connected. Replace 3-4 shift solenoid.
Replace transmission pan and fill with fluid. Start engine and allow
engine and transmission to reach normal operating temperature. Using
scan tool, select GOV and 3-4 SHIFT VALVE SYSTEM TEST. Select 4th gear
while monitoring pressure gauges. Governor pressure should rise to
greater than 20 psi (1.4 kg/cm
) and O/D pressure should rise to
greater than 40 psi (2.8 kg/cm). If pressures are as specified, no
problem is found at this time. Testing is complete. If pressures are
not as specified, see appropriate AUTOMATIC TRANSMISSION OVERHAUL
article, paying attention to seals and clutches related to O/D clutch.
DTC P1740: TCC OR O/D SOLENOID PERFORMANCE (BR BODY - DIESEL)
Circuit Description
Torque Converter Clutch (TCC) and overdrive clutch are tested\
when Powertrain Control Module (PCM) requests TCC engagement in 3rd
gear and overdrive. Code will set if expected RPM drop is not achieved
while attempting to engage TCC and/or overdrive. Code indicates
malfunctioning torque converter or overdrive clutch.
Possible Causes
* Fluid level or quality problem.
* Transmission wiring and connector defective.
* Transmission mechanically defective.
* Low fuel level.
* Trans temperature below 32
.
* Transfer case is in low range.
* Engine RPM trouble codes set.
* Misfire trouble code set (DTCs P0300-P0306).
* Output shaft speed trouble code set.
* PTO is engaged.
* TPS codes set (DTCs P0121-P0123).
* Torque converter defective.
Diagnostic Procedures
1) Using scan tool, read DTCs. If DTC SPECIFIC GOOD TRIPS
counter is not displayed or displayed count is not "0", go to step
16). If DTC SPECIFIC GOOD TRIPS counter is displayed and displayed
count is "0", go to next step.
2) If any DTCs listed are present, perform appropriate
test(s). See TCC OR O/D SOLENOID TESTS table. If no DTCs are present,
go to next step.
TCC OR O/D SOLENOID TESTS









\









\









\









\









\









\









\







DTC Message Test
CAMSHAFT POSITION SENSOR SIGNAL .......................... ( 1) P0341
P/N SWITCH STUCK IN PARK OR IN GEAR .......................... P1899
Any Throttle Position Sensor (TPS) DTC ......................... ( 1)
Any Misfire DTC ................................................ ( 1)
Any Engine RPM DTC ............................................. ( 1)
Any Output Shaft Speed Sensor DTC .............................. ( 1)
TRANS 12-VOLT SUPPLY RELAY CNTRL CIRCUIT ..................... P1765
TORQUE CONVERTOR CLUTCH SOLENOID/TRANS RELAY CIRCUITS ........ P0743
TRANS 3-4 SHIFT SOLENOID/TRANS RELAY CIRCUITS ................ P0753

(1) - See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.








\









\









\









\









\









\









\







3) Ensure fuel tank is at least 1/4 full. If fuel level is
too low, correct fuel level and retest. If fuel level is okay, go to
next step.
4) Ensure transfer case is not in low range. Shift transfer
case out of low range. If transfer case is not in low range, go to
next step.
5) Ensure PTO is not engaged. Disengage PTO. If PTO is not
engaged, go to next step.
6) Ensure transmission fluid temperature is above 32
F (0C).
Warm transmission to normal operating temperature. If transmission
fluid temperature is above 32
F (0C), go to next step.
7) Turn ignition on. Using scan tool, build a custom display
with engine RPM, output shaft SPD, TCC solenoid, O/D solenoid and
throttle position. Set overdrive to off position. Road test vehicle
and reach a steady speed of 55 MPH with a minimum throttle opening
voltage of 1.15 volts for 20 seconds. Note shift patterns while
vehicle is attaining speed. If engine RPM is within 60 RPM of output
shaft speed RPM, go to next step. If engine RPM is not within 60 RPM
of output shaft speed RPM, go to step 15).
8) If output shaft speed RPM is greater than engine RPM, go
to next step. If output shaft speed RPM is equal to or less than
engine RPM, go to step 15).
9) Road test vehicle and reach a steady speed of 55 MPH and
engage overdrive. If engine RPM is 69 percent of output shaft speed,
go to step 15). If engine RPM is not 69 percent of output shaft speed,
go to next step.
10) Connect a 0-300 psi (0-21 kg/cm
) pressure gauge to
transmission Overdrive (O/D) clutch pressure test port. Connect a
second 0-300 psi (0-21 kg/cm
) pressure gauge to transmission governor
pressure test port. See appropriate AUTOMATIC TRANSMISSION OVERHAUL
article. Ensure engine and transmission are at normal operating
temperature. With an assistant, test drive vehicle. Using scan tool,
select GOV and 3-4 SHIFT VALVE SYSTEM TEST. Select 4th gear while
monitoring pressure gauge. Governor pressure should rise to greater
than 20 psi (1.4 kg/cm
) and O/D pressure should rise to greater than
40 psi (2.8 kg/cm). If pressures are as specified, go to next step.
If pressures are not as specified, go to step 13).
11) Check transmission fluid for proper level and for any
debris. Fill or repair transmission as necessary. If fluid level and
condition are okay, go to next step.
12) Drain transmission fluid and remove oil pan. If
transmission fluid is burnt or has excessive debris, repair as
necessary. If transmission fluid is okay, go to step 23).
13) Check transmission fluid for proper level and for any
debris. Fill or repair transmission as necessary. If fluid level and
condition are okay, go to next step.
14) Leave gauges connected. Replace 3-4 shift solenoid. Start
engine and allow engine and transmission to reach normal operating
temperature. Using scan tool, select GOV and 3-4 SHIFT VALVE SYSTEM
TEST. Select 4th gear while monitoring pressure gauges. Governor
pressure should rise to greater than 20 psi (1.4 kg/cm
) and O/D
pressure should rise to greater than 40 psi (2.8 kg/cm). If pressures
are as specified, testing is complete. If pressures are not as
specified, see appropriate AUTOMATIC TRANSMISSION OVERHAUL article,
paying attention to seals and clutches related to O/D clutch.
15) Check transmission fluid for proper level and for any
debris. Fill or repair transmission as necessary. If fluid level and
condition are okay, go to next step.
16) Start engine. Using scan tool, perform TCC SYSTEM TEST.

Fig. 6: Locating Intake Manifold Air Heater
Courtesy of Chrysler Corp.
NOTE: Restricted low-pressure fuel lines from fuel tank to fuel
transfer pump, fuel heater and fuel filter/water separator
may cause starting problems and prevent engine from
accelerating. Restricted high-pressure fuel lines from fuel
injection pump to fuel injector may cause starting problems,
poor engine performance and excessive Black smoke.
11) Check all fuel supply and returns lines for damage,
kinking or leakage. Check throttle linkage for binding. Check for a
stretched or disconnected throttle return spring.
12) Ensure all ground connections are tight and free of
corrosion. Ensure accessory drive belt is not damaged or slipping.
Check for loose or defective electrical connection on Crankshaft
Position (CKP) sensor. See Fig. 1.

13) On A/T models, ensure all electrical connectors are clean
and properly connected to electrical plugs on transmission case. On
all models, check for loose or defective electrical connections on
starter and starter solenoid.
MECHANICAL INSPECTION
Compression
Manufacturer does not provide information for checking
compression.
FUEL SYSTEM
AIR IN FUEL SYSTEM
NOTE: Air in the fuel system may cause hard starting, rough
running, excessive smoke, poor engine performance, engine
misfire, poor fuel economy and fuel knock. Air may enter fuel
system whenever fuel supply lines, fuel filter/water
separator, fuel injection pump, fuel injectors or high
-pressure fuel lines are removed or disconnected.
1) Inspect all low-pressure fuel lines from fuel tank to fuel
transfer pump, fuel heater and fuel filter/water separator for signs
of leakage. Inspect all high-pressure fuel lines for signs of leakage.
See FUEL INJECTOR & HIGH-PRESSURE FUEL LINES under FUEL SYSTEM.
2) After repairing fuel leak, bleed air from fuel system. See
FUEL LINE BLEEDING under FUEL SYSTEM in REMOVAL, OVERHAUL &
INSTALLATION - TRUCKS - DIESEL article.
FUEL HEATER
1) Fuel heater is located in fuel filter/water separator. See
Fig. 1 . Fuel heater uses a fuel heater temperature sensor for
controlling operation of the fuel heater.
2) A defective fuel heater may cause excessive wax build-up
in the fuel filter/water separator during cold ambient temperatures.
Wax build-up may cause hard starting, prevent engine from
accelerating, low power, Blue smoke or White smoke. For testing of
fuel heater and fuel heater temperature sensor, see SYSTEM & COMPONENT
TESTING - TRUCKS - DIESEL article.
FUEL HEATER RELAY
Ensure fuel heater relay, located in power distribution
center is installed correctly and that terminals are not corroded. For
fuel heater relay testing, see SYSTEM & COMPONENT TESTING - TRUCKS -
DIESEL article.
FUEL FILTER/WATER SEPARATOR
NOTE: A blocked or restricted fuel filter/water separator may cause
starting problems, prevent engine from accelerating, low
power or White smoke. If an excessive amount of water
collects in filter/separator in a short period of time, it
may be necessary to drain and clean fuel tank.
1) When ignition switch is first turned to ON position,
WATER-IN-FUEL (WIF) warning light should come on for 2 seconds to
perform bulb and wiring circuit test and then go off. WATER-IN-FUEL
(WIF) warning light is located on instrument panel, just below the

tachometer.
2) If WATER-IN-FUEL (WIF) warning light stays on, water
should be drained from fuel filter/water separator. To drain water
from fuel filter/water separator, ensure engine is not running. Place
drain pan below drain tube at fuel filter/water separator. See Fig. 1.
3) Rotate handle on drain valve forward, toward front of
vehicle to OPEN position. Drain valve is located near top of fuel
filter/water separator. See Fig. 1.
4) Allow water to drain until clean flow of diesel fuel
exists. Rotate handle on drain valve back to CLOSE position.
FUEL TRANSFER PUMP
NOTE: A defective fuel transfer pump may cause low power, hard
starting and White smoke. Check fuel transfer pump output
pressure (cranking and starting), pressure drop and fuel
supply.
Fuel Transfer Pump Preliminary Inspection
1) Check for restricted or leaking fuel supply line to fuel
transfer pump or fuel return line located on driver's side of engine.
See Fig. 1 . Repair fuel supply line or fuel return line if restricted
or leaking.
2) Check for fuel leaking from fuel transfer pump. Replace
fuel transfer pump if fuel is leaking. Check fuel transfer pump output
pressure.
Fuel Transfer Pump Output Pressure
1) Clean area around filter fitting plugs, then remove plugs.
See Fig. 7 . Install Test Fittings (AVU1-2). Install Fuel Pressure Test
Gauge (6828) at inlet port. See Fig. 7. To prevent engine starting,
remove fuel injection pump relay, located in power distribution
center.
2) Turn ignition switch to START position. Inlet pressure
should be 5-7 psi. Install fuel injection pump relay. Start engine.
Inlet pressure should be 10 psi. Using a scan tool, clear FTC. FTC may
set when relay is removed. Check pressure drop.
Fig. 7: Checking Fuel Transfer Pump Output Pressure
Courtesy of Chrysler Corp.
Pressure Drop Test
Turn engine off. Move pressure gauge from inlet port to

outlet port. See Fig. 7. Start engine. Outlet pressure should not be
more 5 psi (0.4 kg/cm) less than inlet pressure. If pressure drop is
more than 5 psi (0.4 kg/cm), replace fuel filter and retest pressure.
If pressure drop is less than 5 psi (0.4 kg/cm), check for fuel
supply restriction.
NOTE: Due to very small vacuum specifications, use a scan tool and
Periphal Expansion Port (PEP) module with 0-15 psi transducer\
to perform following test.
Fuel Supply Restriction Test
Ensure transfer pump pressure is okay. Disconnect fuel supply
line at fuel transfer pump inlet. Remove plastic clip from pump inlet
and install in end of fuel supply line. Install 3/8" Adapter Hose
(6631) between fuel supply line and pump inlet. Install transducer
from PEP module to "T" fitting on adapter. Connect scan tool to
module. Start engine. Check vacuum reading with engine at full
throttle with no load. If vacuum reading is less than 6 in. Hg, check
for fuel supply air leaks. If vacuum reading is 6 in. Hg or more,
check fuel line for damage, dents and kinks. Repair as necessary. If
no problem is found, remove fuel module from fuel tank and check for
obstructions. Repair as necessary.
NOTE: A 3' section of 1/4" I.D. clear tubing and a 1/8" NPT fitting
are required for the following test.
Fuel Supply Air Leak Test
Clean area around filter inlet fitting plug, then remove
plug. See Fig. 7. Install 1/8" NPT fitting with 1/4" nipple fitting in
test port. Attach clear hose with a clamp to fitting. Place other end
of hose in a fuel container. Turn ignition switch to START position,
then release to RUN position without starting engine. Fuel transfer
pump should run for 25 seconds. After hose has been purged, watch for
any air bubbles in hose. If no bubbles exist, system is okay. If
bubbles exist, check fuel line, fittings and fuel module in tank.
Repair as necessary.
OVERFLOW VALVE
1) Fuel transfer pump delivers more fuel to fuel injection
pump than needed. Surplus fuel is routed back to fuel tank by overflow
valve. Overflow valve is used to secure fuel return line to side of
fuel injection pump. See Fig. 1. A sticking check valve in the
overflow valve may result in low power. Pressure release is set at 14
psi. (1.0 kg/cm
). If outlet valve is stuck closed, a FTC may set.
2) Clean area around outlet valve and fuel return line.
Remove valve from pump and fitting. Using regulated air pressure, test
valve by blowing into valve inlet. Valve should open at 14-16 psi. (1.
0-1.1 kg/cm
). If valve does not open, replace valve. Reduce air
pressure to 10 psi. (0.7 kg/cm). Valve should close. If valve does
not close, replace valve. Using NEW gaskets, install valve through
banjo fitting into fuel injection pump. Tighten valve to 24 ft. lbs.
(30 N.m).
FUEL INJECTOR & HIGH-PRESSURE FUEL LINES
WARNING: DO NOT allow diesel fuel to contact hot engine when checking
fuel injector, as high exhaust temperatures could cause fire.
Use care when working around high-pressure fuel lines, as
fuel is under extreme pressure and could penetrate skin,
causing personal injury. Wear safety goggles and protective
clothing when checking fuel injectors.