NOTE: Whenever transmission or drivetrain service is performed
that affects the suspension alignment, for example,
removing the engine cradle, it is required that the
alignment be checked and corrected if necessary.
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLY INSPECTION \
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Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ........... ( 2) Require repair or
replacement of the automatic
transmission/transaxle
assembly.
( 1) - It is Required that the torque converter and all other
failure related components be inspected for cause and
condition.
( 2) - For components not requiring removal of the assembly,
refer to the component listing in this document.
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DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES
NOTE: Does not include half shafts.
DIFFERENTIAL AND FINAL DRIVE ASSEMBLY INSPECTION
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Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ... Require repair or replacement
of the differential assembly.
( 1) - For components not requiring removal of the assembly,
refer to the component listing in this document.
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MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLY INSPECTION \
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Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ... Require repair or replacement
of the manual
transmission/transaxle
assembly.
( 1) - For components not requiring removal of the assembly,
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) - Inoperative includes intermittent operation or out of OEM
specification. Some components may be serviceable; check
for accepted cleaning procedure.
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CRUISE CONTROL BRAKE SWITCHES
See SWITCHES.
CRUISE CONTROL CABLES
See CRUISE CONTROL LINKAGES AND CABLES .
CRUISE CONTROL CLUTCH SWITCHES
See SWITCHES.
CRUISE CONTROL LINKAGES AND CABLES
CRUISE CONTROL LINKAGE AND CABLE INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Bent .................... A .. Require repair or replacement.
Binding ................. A .. Require repair or replacement.
Bracket bent, affecting
performance ............ A .. Require repair or replacement.
Bracket bent, not
affecting performance .. .. ........ No service suggested or
required.
Bracket broken, affecting
performance ............ A ............ Require replacement.
Bracket broken, not
affecting performance .. .. ........ No service suggested or
required.
Bracket corroded,
affecting performance .. A .. Require repair or replacement.
Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
(8) - One used on vehicles with light-duty emissions. Two used on
vehicles with heavy-duty emissions.
(
9) - Used on vehicles with heavy-duty emissions.
(
10 ) - Two catalytic converters are required.
(
11 ) - Four sensors used on vehicles with medium-duty emissions.
Two sensors used on vehicles with heavy-duty emissions.
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ABBREVIATIONS
ABBREVIATION DEFINITIONS\
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Abbreviation Definition
AIH ................................... Air Intake Heaters
AIH-TS ............................ AIH Temperature Sensor
AP ............................. Air Pump Injection System
AP-CKV .................................... AP Check Valve
AP-RV .................................... AP Relief Valve
BP/EGR ........................... Backpressure EGR System
BP/EGR-BPT ................ BP/EGR Backpressure Transducer
CCV ................................ Crankcase Ventilation
CEC ......................... Computerized Engine Controls
CNG ............................... Compressed Natural Gas
EFI ............................ Electronic Fuel Injection
EGR-CKV .................................. EGR Check Valve
EVAP ............................. Fuel Evaporative System
EVAP-CVV ........................ EVAP Canister Vent Valve
EVAP-LDP ........................ EVAP Leak Detection Pump
EVAP-LDPF ................ EVAP Leak Detection Pump Filter
EVAP-PRRV ............ EVAP Pressure Relief Rollover Valve
EVAP-PSOL ............................ EVAP Purge Solenoid
EVAP-VC .............................. EVAP Vapor Canister
EVAP-VV ........................... EVAP Ventilation Valve
FR ................................... Fillpipe Restrictor
HO2S ................................ Heated Oxygen Sensor
MIL .......................... Malfunction Indicator Light
PCV ....................... Positive Crankcase Ventilation
SFI .................. Sequential Multiport Fuel Injection
SPK ....................................... Spark Controls
SPK-CC ........................... SPK Computer Controlled
TWC ........................ Three-Way Catalytic Converter
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EM IS SIO N C O NTR O L V IS U AL IN SPEC TIO N P R O CED URES
1999 D odge P ic ku p R 1500
1983-98 GENERAL INFORMATION
Emission Control Visual Inspection Procedures
All Models
* PLEASE READ THIS FIRST *
This article is provided for general information only. Not
all information applies to all makes and models. For more complete
information, see appropriate article(s) in the ENGINE PERFORMANCE
Section.
EMISSION CONTROL LABELS
The vehicle manufacturer's emission control label, also known
as the underhood tune-up label or Vehicle's Underhood Emission Control
System (VECI) label, is located in the engine compartment. Information\
regarding year model of vehicle, engine size, number of cylinders,
emission equipment or type, engine tune-up specifications, whether
vehicle was manufactured for sale in California or is a Federal
vehicle, vacuum hose routing schematic, etc., can be found on this
label. See Fig. 1.
In addition to the VECI label, some emission control
inspection and maintenance programs may require an additional label to
be affixed to the vehicle in special circumstances. For example, in
California, a Bureau Of Automotive Repair (BAR) engine label may be
affixed to the left door post. A BAR engine label is only used when
the vehicle has an engine change, approved modification or is a
Specially Constructed (SPCN) or an acceptable Gray market vehicle.
Check your state's emission control inspection and maintenance laws to
determine if a similar label is used.
Fig. 1: Typical Emission Control Label
Courtesy of General Motors Corp.
EMISSION CONTROL VISUAL INSPECTION
* PLEASE READ THIS FIRST *
NOTE: The following emission control visual inspection procedures
should be used as a guide only. When performing a visual
inspection, always follow your state's recommended
inspection procedures.
A visual inspection is made to determine if any required
emission control devices are missing, modified or disconnected.
Missing, modified or disconnected systems must be made fully
operational before a vehicle can be certified.
POSITIVE CRANKCASE VENTILATION (PCV)
PCV controls the flow of crankcase fumes into the intake
manifold while preventing gases and flames from traveling in the
opposite direction. PCV is either an open or closed system. See Fig. 2
.
Ensure PCV system is installed as required. Verify valve,
required hoses, connections, flame arresters, etc., are present,
routed properly and in serviceable condition.
Fig. 2: Typical Open & Closed Type PCV System
THERMOSTATIC AIR CLEANER (TAC)
The TAC supplies warm air to air intake during cold engine
operation. This system is active during cold engine warm-up only.
Under all other operating conditions, air cleaner function is the same
as any non-thermostatic unit.
Ensure required exhaust shroud, hot air duct, vacuum hoses
and air cleaner components are present and installed properly. See
Fig. 3 . Ensure any required thermostatic vacuum switches are in place
and vacuum hoses are installed and in serviceable condition. Also
ensure air cleaner lid is installed right side up. Check for oversized
air filter elements and for additional holes in the air cleaner
housing.
Fig. 3: Typical Thermostatic Air Cleaner System
FUEL EVAPORATIVE SYSTEM (EVAP)
The EVAP system allows for proper fuel system ventilation
while preventing fuel vapors from reaching the atmosphere. This means
that vapors must be caught and stored while the engine is off, which
is when most fuel evaporation occurs. When the engine is started,
these fuel vapors can be removed from storage and burned. In most
systems, storage is provided by an activated charcoal (or carbon)
canister. See Fig. 4. On a few early systems, charcoal canisters are
not used. Instead, fuel vapors are vented into the PCV system and
stored inside the crankcase.
The main components of a fuel evaporation system are a sealed
fuel tank, a liquid-vapor separator and vent lines to a vapor-storing
canister filled with activated charcoal. The filler cap is normally
not vented to the atmosphere, but is fitted with a valve to allow both
pressure and vacuum relief.
Although a few variations do exist between manufacturers,
basic operation is the same for all systems. Check for presence of
vapor storage canister or crankcase storage connections when required.
Ensure required hoses, solenoids, etc., are present and connected
properly. Check for proper type fuel tank cap. Check for any non-OEM
or auxiliary fuel tanks for compliance and the required number of
evaporation canisters.
Spark control systems are designed to ensure the air/fuel
mixture is ignited at the best possible moment to provide optimum
efficiency and power and cleaner emissions.
Ensure vacuum hoses to the distributor, carburetor, spark
delay valves, thermal vacuum switches, etc., are in place and routed
properly. On Computerized Engine Controls (CEC), check for presence of\
required sensors (O2, MAP, CTS, TPS, etc.). Ensure they have not been
tampered with or modified.
Check for visible modification or replacement of the feedback
carburetor, fuel injection unit or injector(s) with a non-feedback
carburetor or fuel injection system. Check for modified emission-
related components unacceptable for use on pollution-controlled
vehicles.
AIR INJECTION SYSTEM (AIS)
Air Pump Injection System (AP)
The air pump is a belt-driven vane type pump, mounted to
engine in combination with other accessories. The air pump itself
consists of the pump housing, an inner air cavity, a rotor and a vane
assembly. As the vanes turn in the housing, filtered air is drawn in
through the intake port and pushed out through the exhaust port. See
Fig. 13 .
Check for missing or disconnected belt, check valve(s),
diverter valve(s), air distribution manifolds, etc. Check air
injection system for proper hose routing.
Fig. 13: Typical Air Pump Injection System
Courtesy of General Motors Corp.
Pulsed Secondary Air Injection (PAIR) System
PAIR eliminates the need for an air pump and most of the
associated hardware. Most systems consists of air delivery pipe(s),
pulse valve(s) and check valve(s). The check valve prevents exhaust
gases from entering the air injection system. See Fig. 14.
Ensure required check valve(s), diverter valve(s), air
distribution manifolds, etc., are present. Check air injection system
for proper hose routing.
EARLY FUEL EVAPORATION (EFE)
The EFE valve is actuated by either a vacuum actuator or a
bimetal spring (heat-riser type). The EFE valve is closed when engine
is cold. The closed valve restricts exhaust gas flow from the exhaust
manifold. This forces part of the exhaust gas to flow up through a
passage below the carburetor. As the exhaust gas quickly warms the
intake mixture, distribution is improved. This results in better cold
engine driveability, shorter choke periods and lower emissions.
Ensure EFE valve in exhaust manifold is not frozen or rusted
in a fixed position. On vacuum-actuated EFE system, check EFE thermal
vacuum valve and check valve(s). Also check for proper vacuum hose
routing. See Fig. 15.
Fig. 15: Typical Vacuum-Actuated EFE System
Courtesy of General Motors Corp.
EMISSION MAINTENANCE REMINDER LIGHT (EMR) (IF EQUIPPED)