radiator cap DODGE RAM 1999 Service Repair Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 161 of 1691
VALVES. Connect 2 hoses with shutoff valves to manifold gauge set
center port. Connect one hose to vacuum pump and other hose to
refrigerant container. Weight of refrigerant container before and
after charging can be used to determine amount of refrigerant drawn
into system. Using vacuum pump, purge air from center hoses.
3) Fully open manifold gauge set low-side valve and
refrigerant container valve to allow refrigerant to enter A/C system.
When no more refrigerant is being drawn into A/C system, start engine
and allow to idle. Select MAX A/C, set blower motor speed to maximum
and allow remaining refrigerant to be drawn into A/C system.
NOTE: When ambient air temperature is high, it may be necessary to
use an external cooling fan to blow air through condenser and
radiator.
4) When proper amount of refrigerant has been added, close
refrigerant container valve. Allow any refrigerant remaining in hose
to be drawn into A/C system. When low-side pressure decreases to about
30 psi (2.1 kg/cm
), close center valve on manifold gauge set. Ensure
A/C system is operating properly. Disconnect manifold gauge set.
Install service port caps. Check system for leaks. See LEAK TESTING.
GENERAL MOTORS
Manufacturer recommends using A/C Refrigerant Recovery,
Recycling And Recharging (ACR4) System (J-39500). The ACR4 system ha\
s
one filtering cycle during recovery plus an automatic multiple pass
filtering during evacuation cycle. Follow manufacturer's instructions
provided with ACR4 equipment being used.
JEEP
Connect recovery/recycling equipment, meeting SAE standard
J1991 or J2210, to vehicle. Charge A/C system to specifications, using
equipment manufacturer's instructions.
LEAK TESTING
TYPES OF LEAK DETECTORS
Bubble Solution Detector
This is a solution applied externally at suspected leak
points. Leaking refrigerant will cause the detector to form bubbles
and foam. A soap and water solution also works well.
Dye Solution
This is a colored solution that may be introduced into the
A/C system. The dye will show up and color components at leak points.
Some manufacturers offer refrigerant containing a Red dye. This dye-
containing refrigerant is installed by normal charging procedures.
Other dye solutions are visible with a Black light only.
Electronic Leak Detector
This instrument will draw in any leaking refrigerant through
a test probe, and then sound an audible signal or create a flashing
light if refrigerant is found. It is the most sensitive of the leak
detectors used. Leak detectors are sensitive to windshield washing
solutions, many solvents and cleaners, and some adhesives. Ensure
surfaces near test areas are clean and dry to prevent false signal or
detector damage. Liquids ingested into detector will damage detector.
See Fig. 24 .
Page 460 of 1691
1) On drive shafts greater than 30" in length, measure runout
3" from transmission flange/yoke, center bearing yoke and pinion
flange using dial indicator. Maximum runout for Ram Pickup is .030" (.
76 mm) at front and rear end of drive shaft and .035" (.89 mm) at
center of drive shaft. Maximum runout for all other models is .010" (.
25 mm) at front and rear end of drive shaft and .015" (.38 mm) at
center of drive shaft.
2) For drive shafts less than 30" in length, maximum runout
for Pickup is .030" (.76 mm). Maximum runout for all other models is .\
020" (.51 mm). Replace drive shaft if maximum runout is exceeded.
BALANCING DRIVE SHAFT
1) Perform following procedure only after inspecting all
other possible causes of vibration. See INSPECTION. Drive shaft
imbalance may often be cured by disconnecting shaft, rotating it 180
degrees and reconnecting shaft to flange. Test drive to check results.
NOTE: DO NOT run engine for prolonged periods without forced
airflow across radiator. Engine or transmission may
overheat.
2) To balance drive shaft(s), begin by raising rear wheels
off ground and turning drive shaft with engine. Balance testing may be
done by marking drive shaft in 4 positions, 90 degrees apart around
shaft. Place marks about 6" forward of rear flange/yoke weld. Number
marks 1-4.
3) Install large diameter screw-type hose clamp around drive
shaft so clamp's head is in No. 1 position. Spin drive shaft with
engine and note vibrations. If there is little or no change in
vibration intensity, move clamp head to No. 2 position, and repeat
test.
4) Continue procedure until vibration is at lowest level. If
no difference is noted with clamp head moved to all 4 positions,
vibrations may not be due to drive shaft imbalance.
5) If vibration decreases but is not completely eliminated,
place a second clamp at same position, and repeat test. Combined
weight of both clamps in one position may increase vibration. If so,
rotate clamps 1/2" apart, above and below lowest vibration level
position, and repeat test.
6) Continue to rotate clamps, as necessary, until vibration
is at lowest point. If vibration can be eliminated or reduced to
acceptable level, bend back slack end of clamp so screw cannot loosen.
If vibration level is still unacceptable, leave rear clamp(s) in
place, and repeat procedure at front end of drive shaft. Road test
vehicle. On 4WD models, perform procedure on each shaft.
CHECKING VERTICAL ANGLE
One-Piece Drive Shafts
1) Raise and support vehicle so rear wheels can be rotated.
Rotate drive shaft so a pinion flange bearing cap faces downward.
Attach Inclinometer (C-4224) magnet to bearing cap, and measure drive
shaft vertical angle. See Fig. 4. Remove inclinometer.
2) Rotate drive shaft 90 degrees until drive shaft rear yoke
bearing cap faces downward. Attach inclinometer magnet to bearing cap,
and measure drive shaft vertical angle. Difference between 2 measured
angles is drive shaft rear angle. See Fig. 5. Remove inclinometer.
3) Rotate drive shaft until a slip joint yoke bearing cap
faces downward. Attach inclinometer magnet to bearing cap, and note
angle. Remove inclinometer. Rotate drive shaft 90 degrees until drive
shaft front yoke bearing cap faces downward. Attach inclinometer
magnet to bearing cap, and note angle. Remove inclinometer.
Page 627 of 1691
COOLING SYSTEM BLEEDING
GASOLINE ENGINES
Air in system will collect under radiator cap. As engine
reaches operating temperature, coolant and any trapped air will enter
reserve tank. As engine cools, a vacuum will be created which will
draw only coolant into cooling system. After engine has gone through a
warm-up and cooling cycle, run engine until it again reaches operating
temperature. Ensure coolant in reserve tank is at warm coolant mark on
reserve tank or dipstick.
5.9L DIESEL ENGINE
For bleeding procedures on 5.9L diesel, see appropriate 12-
valve or 24-valve engine article in ENGINES. DO NOT operate engine
while filling cooling system.
SPECIFICATIONS
COOLING SYSTEM SPECIFICATIONS
COOLING SYSTEM SPECIFICATIONS - CARS \
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Application Specification
Avenger & Sebring Coupe
Coolant Replacement Interval ........... 30,000 Miles Or 24 Months
Coolant Capacity ................................. 7.4 Qts. (7.0L)\
Pressure Cap .............................................. 16 psi
Thermostat
DOHC
Starts To Open ................................... 195
F (91C)
Fully Opens ..................................... 216F (102C)
SOHC
Starts To Open ................................... 180
F (82C)
Fully Opens ...................................... 203F (95C)
Breeze, Cirrus, Sebring Convertible & Stratus
Coolant Replacement Interval ........... 45,000 Miles Or 36 Months
Coolant Capacity
2.0L ............................................ 8.5 Qts. (8.0L)\
2.4L ............................................ 9.0 Qts. (8.5L)\
2.5L .......................................... 10.5 Qts. (10.0L)\
Pressure Cap ........................................... 14-18 psi
Thermostat
Starts To Open .............................. 192-199
F (88-93C)
Fully Opens ....................................... 220F (104C)
Concorde, Intrepid, LHS & 300M
Coolant Replacement Interval ....................... 120,000 Miles
Coolant Capacity ................................. 9.4 Qts. (8.9L)\
Pressure Cap ........................................... 14-18 psi
Thermostat
Starts To Open .............................. 192-199
F (88-93C)
Fully Opens ....................................... 220F (104C)
Neon
Coolant Replacement Interval ........... 45,000 Miles Or 36 Months
Coolant Capacity ................................. 7.4 Qts. (7.0L)\
Pressure Cap ........................................... 14-18 psi
Thermostat
Starts To Open .............................. 192-199
F (88-93C)
Fully Opens ....................................... 220F (104C)
Page 633 of 1691
Fig. 2: Identifying Retainer Type Fuel Line Disconnect Fittings
Courtesy of Chrysler Corp.
ENGINE
Removal (Ram Van/Wagon)
1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect negative battery cable. Drain cooling system and engine
oil. Remove and discard oil filter.
2) Remove engine cover, air cleaner and oil dipstick.
Discharge A/C system (if equipped) using approved refrigerant
recovery/recycling equipment. Disconnect A/C lines at condenser, and
plug openings. Remove A/C compressor. Disconnect fan shroud.
3) Remove front bumper, grille and support brace. Disconnect
coolant hoses. Remove radiator, condenser and support as an assembly.
4) Remove upper fan shroud. Remove power steering pump with
hoses attached, and set aside. Remove air pump, spark plug wires and
distributor cap. Disconnect necessary electrical wiring, coolant hoses
and vacuum hoses. Disconnect fuel lines. See FUEL LINE DISCONNECT
Page 634 of 1691
FITTINGS. Remove air cleaner, throttle body, drive belts, generator,
fan and fan pulley. Remove lower fan shroud.
CAUTION: When removing engine, DO NOT lift engine by intake manifold.
5) Remove intake manifold. See INTAKE MANIFOLD. Raise and
support vehicle. Remove starter. Remove exhaust pipe and heat shields.
Disconnect transmission shift linkage. Remove crank sensor.
6) On A/T models, remove transmission inspection cover. Mark
torque converter-to-flexplate position for installation reference.
Remove torque converter-to-flexplate bolts. On M/T models, disconnect
clutch release mechanism at clutch housing.
7) Attach engine hoist to cylinder heads (at intake manifold
flanges). On all models, support transmission using a floor jack.
Remove transmission or clutch housing-to-cylinder block bolts. Remove
engine mount bolts. Remove engine out front of vehicle.
Installation
To install, reverse removal procedure. Tighten bolts/nuts to
specification. See TORQUE SPECIFICATIONS table. On A/T models, ensure
reference marks on torque converter and flexplate are aligned.
Evacuate and charge A/C system.
Removal ( Dakota 2WD, Durango 2WD, Grand Cherokee & Ram
Pickup)
1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect and remove battery. On all except Pickup, scribe hood
hinges for installation reference and remove hood.
2) On all models, drain cooling system. Disconnect coolant
hoses. Remove radiator, fan and shroud. Discharge A/C system (if
equipped) using approved refrigerant recovery/recycling equipment.
Disconnect A/C lines, and plug openings. On Pickup, remove upper core
support, transmission cooler and A/C condenser. On all models, remove
belt, air cleaner, vacuum lines, distributor cap and wiring.
3) Disconnect necessary electrical wiring. Disconnect fuel
lines. See FUEL LINE DISCONNECT FITTINGS. Remove throttle body and
linkage. Remove intake manifold. Remove starter, generator, charcoal
canister and horns. Disconnect power steering hoses (if equipped).
Raise and support vehicle. Drain oil. Disconnect exhaust pipe at
exhaust manifold.
4) On A/T models, remove transmission housing inspection
plate. Mark torque converter-to-flexplate position for installation
reference. Remove torque converter-to-flexplate bolts. Remove bracket
for transmission cooler lines.
NOTE: It may be necessary to remove manual transmission if
transmission cannot be supported using floor jack.
5) On M/T models, disconnect clutch release mechanism at
clutch housing. On all models, support transmission using a floor
jack. Remove transmission or clutch housing-to-cylinder block bolts.
Install engine lifting fixture, and attach chain.
CAUTION: When removing engine, DO NOT lift engine by intake manifold.
6) On Ram Pickup and Grand Cherokee, remove front engine
mount bolts. Remove engine from vehicle. On Dakota 2WD and Durango 2WD
models, remove front engine mount through-bolts. See Fig. 3. Remove
engine from vehicle.
Installation
To install, reverse removal procedure. Tighten bolts/nuts to
specification. See TORQUE SPECIFICATIONS table. On A/T models, ensure
Page 635 of 1691
reference marks on torque converter and flexplate are aligned.
Evacuate and charge A/C system.
Removal (Durango 4WD & Dakota 4WD)
1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect and remove battery. Scribe hood hinges for installation
reference and remove hood.
2) Drain cooling system. Disconnect coolant hoses. Remove
radiator, fan and shroud. Discharge A/C system (if equipped) using
approved refrigerant recovery/recycling equipment. Disconnect A/C
lines, and plug openings. Remove air cleaner, vacuum lines,
distributor cap and wiring.
3) Disconnect necessary electrical wiring. Disconnect fuel
lines. See FUEL LINE DISCONNECT FITTINGS. Disconnect accelerator
linkage. Remove throttle body. Remove starter and generator.
Disconnect power steering hoses. Raise and support vehicle. Drain oil.
Disconnect exhaust pipe at exhaust manifold.
NOTE: Engine, transmission and front axle are connected and
supported with insulators and brackets. See Fig. 3.
4) On left side, remove 2 bolts attaching differential pinion
nose bracket-to-bellhousing bolts. Remove pinion nose bracket-to-
adapter bolts (located on top of differential, near pinion). Separate
engine from engine mount by removing engine mount through-bolt and nut
located on top of engine mount.
5) On right side, remove 2 axle-to-bracket bolts and bracket-
to-bellhousing bolt. Separate engine from engine mount by removing
engine mount through-bolt and nut located on top of engine mount.
Remove engine from vehicle.
Page 706 of 1691
FUEL TANKS
GAS CAPS
GASKETS
GROMMETS (VALVE COVER)
HARMONIC DAMPERS
HEATER CONTROL VALVES
HEATER CORES
HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS
HOSE CLAMPS
HOSE CONNECTORS
HOSE COUPLERS
HOSES AND TUBES (FUEL LINES, RADIATOR, VACUUM, BY PASS,
HEATER, RECOVERY TANK AND OIL COOLERS)
HOUSINGS
IDLE AIR CONTROLS
IDLE SPEED CONTROL ACTUATORS
IGNITION BOOTS
IGNITION COIL TOWERS
IGNITION COILS
IGNITION CONTROL MODULES (ICM)
IGNITION SWITCHES
IGNITION TERMINALS
IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY)
IN-TANK FUEL STRAINERS
INERTIA FUEL SHUT-OFF SWITCHES
INTAKE AIR TEMPERATURE SENSORS
INTAKE MANIFOLDS
INTERCOOLERS
KNOCK SENSORS
LIQUID VAPOR SEPARATORS
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORS
MASS AIR FLOW (MAF) SENSORS
METAL AIR MANIFOLDS AND PIPES
METAL AIR PIPES
MIX CONTROL SOLENOIDS
MOTOR MOUNTS
O-RINGS, GASKETS, SEALS AND SPRING LOCKS
O2 SENSORS
OIL PRESSURE SENDING UNITS
OIL PUMP PICK-UP SCREENS
OIL PUMPS
PARK NEUTRAL POSITION SWITCHES
PCV BREATHER ELEMENTS
PCV ORIFICES
PCV VALVES
PICK-UP ASSEMBLIES (INCLUDES MAGNETIC, HALL EFFECT AND
OPTICAL)
POWER STEERING PRESSURE SENSORS
POWERTRAIN CONTROL MODULES (PCM) AND PROM
POWERTRAIN CONTROL PROM
PRESSURIZED EXPANSION TANK CAPS
RADIATOR CAPS AND PRESSURIZED EXPANSION TANK CAPS
RADIATOR FAN BLADES
RADIATOR FAN CLUTCHES
RADIATORS
ROLL OVER VALVES
SEALING COMPOUNDS
SEALS
SECONDARY AIR INJECTION SYSTEM MANAGEMENT DEVICES
SENSORS AND ACTUATORS
SHROUDS, BAFFLES AND DEFLECTORS
SPARK PLUGS
SPRING LOCKS
Page 785 of 1691
Terminal burned, affecting
performance ............ A ........... (2) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
( 1) - Refer to manufacturer's diagnostic trouble code
procedure and require repair or replacement of affected
component(s).
( 2) - Determine cause and correct prior to repair or
replacement of part.
( 3) - Determine source of contamination, such as engine coolant,
fuel, metal particles, or water. Require repair or
replacement.
( 4) - Includes inoperative, intermittent operation, failure to
perform all functions, or out of OEM specification.
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POWERTRAIN CONTROL PROM
See POWERTRAIN CONTROL MODULES (PCM) AND PROM .
PRESSURIZED EXPANSION TANK CAPS
See RADIATOR CAPS AND PRESSURIZED EXPANSION TANK CAPS .
RADIATOR CAPS AND PRESSURIZED EXPANSION TANK CAPS
RADIATOR CAP AND PRESSURIZED EXPANSION TANK CAP INSPECTION \
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Condition Code Procedure
Application incorrect ... B ........... Require replacement.
Coolant recovery check
valve inoperative ...... A ....... ( 1) Require replacement.
Fails to maintain proper
pressure ............... B ........... Require replacement.
Gasket missing .......... C . Require replacement of gasket.
Missing ................. C ........... Require replacement.
Seal missing ............ C ... Require replacement of seal.
( 1) - Inoperative includes intermittent operation or out of
OEM specification.
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RADIATOR FAN BLADES
Page 820 of 1691
GEN ER AL C O OLIN G S YSTE M S ER VIC IN G
1999 D odge P ic ku p R 1500
GENERAL INFORMATION
General Cooling System Servicing
* PLEASE READ THIS FIRST *
The following article is for general information only.
Information may not apply to all years, makes and models. See specific
article in the ENGINE COOLING section.
DESCRIPTION
The basic liquid cooling system consists of a radiator, water
pump, thermostat, electric or belt-driven cooling fan, pressure cap,
heater, and various connecting hoses and cooling passages in the block
and cylinder head.
MAINTENANCE
DRAINING
Remove radiator cap and open heater control valve to maximum
heat position. Open drain cocks or remove plugs in bottom of radiator
and engine block. In-line engines usually have one plug or drain cock,
while "V" type engines will have 2, one in each bank of cylinders.
CLEANING
A good cleaning compound removes most rust and scale. Follow
manufacturer's instructions in the use of cleaner. If considerable
rust and scale has to be removed, cooling system should be flushed.
Clean radiator air passages with compressed air.
FLUSHING
CAUTION: Some manufacturers use an aluminum and plastic radiator.
Flushing solution must be compatible with aluminum.
Back Flushing
Back flushing is an effective means of removing cooling
system rust and scale. The radiator, engine and heater core should be
flushed separately.
Radiator
To flush radiator, connect flushing gun to water outlet of
radiator and disconnect water inlet hose. To prevent flooding engine,
use a hose connected to radiator inlet. Use air in short bursts to
prevent damage to radiator. Continue flushing until water runs clear.
Engine
To flush engine, remove thermostat and replace housing.
Connect flushing gun to water outlet of engine. Flush using short air
bursts until water runs clean.
Heater Core
Flush heater core as described for radiator. Ensure heater
control valve is set to maximum heat position before flushing heater.
Page 821 of 1691
REFILLING
To prevent air from being trapped in engine block, engine
should be running when refilling cooling system. After system is full,
continue running engine until thermostat is open, then recheck fill
level. Do not overfill system.
TESTING
THERMOSTAT
1) Visually inspect thermostat for corrosion and proper
sealing of valve and seat. If okay, suspend thermostat and thermometer
in a 50/50 mixture of coolant and water. See Fig. 1. Do not allow
thermostat or thermometer to touch bottom of container. Heat water
until thermostat just begins to open.
2) Read temperature on thermometer. This is the initial
opening temperature and should be within specification. Continue
heating water until thermostat is fully open and note temperature.
This is the fully opened temperature. If either reading is not to
specification, replace thermostat.
Fig. 1: Testing Thermostat in Anti-Freeze/Water Solution
PRESSURE TESTING
A pressure tester is used to check both radiator cap and