1999 DODGE RAM fuel filter

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REPLACEMENT INTERVALS (RAM PICKUP - MEDIUM & HEAVY DUTY - 5.9L
DIESEL) (1)









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Component Months Miles
Air Filter ............................... ( 2) ............... ( 2)
Coolant .................................. ( 3) ............... ( 3)
Engine Oil & Filter
Normal Service .......................... 6 ............... 7500
Severe Service ......................... ( 4) .............. 3750
Fuel Filter
Normal Service .......................... 12 ............ 15,000
Severe Service ......................... ( 4) .............. 7500
Valve Clearance Adjustment ............... ( 5) ............... ( 5)
Automatic Transmission Fluid,
Filter & Band Adjustment
Normal Service .......................... 24 ............ 30,000
Severe Service ......................... ( 4) ............ 15,000
Manual Transmission Fluid ................ ( 6) ............... ( 6)
Transfer Case Fluid (4WD)
Normal Service .......................... 36 ............ 45,000
Severe Service ......................... ( 4) ............ 36,000
Front Differential Fluid (4WD) ( 7)
Severe Service ......................... ( 4) ............ 15,000
Rear Differential Fluid ( 7)
Severe Service ......................... ( 4) ............ 15,000
Repack Front Wheel Bearings (2WD)
Normal Service .......................... 24 ............ 30,000
Severe Service ......................... ( 4) ............ 30,000
Normal Service .......................... 48 ............ 48,000
Severe Service ......................... ( 4) ............ 48,000
( 1) - Different interval may be required for normal and severe
service. Severe service is described as long periods of engine
idling, frequent short trip operation of less than 5 miles,
trailer towing, off-highway operation, snow removal operation,
or operating in dusty or excessively hot conditions.
( 2) - Service interval is not available from manufacturer. Use filter-
minder on top of air cleaner housing to determine condition of
air filter. If filter-minder is in the Red zone, replace air
filter. Reset filter-minder by depressing button on top of
filter-minder.
( 3) - Replace coolant at 30,000 miles or 24 months whichever occurs
first. Replace coolant at 24 months regardless of mileage. After
first coolant change, replace coolant every 24 months or 30,000
miles thereafter.
( 4) - Monthly interval is not available from manufacturer.
( 5) - Does not require routine adjustments.
( 6) - Service interval is not available from manufacturer.
( 7) - Normal service interval is not available from manufacturer.
Manufacturer lists service schedule only under severe service
conditions.









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REPLACEMENT INTERVALS (RAM VAN & RAM WAGON) ( 1)








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Component Months Miles
Air Filter
Normal Service ................... 24 ................... 30,000
Severe Service ................... ( 2) .............. ( 3) 15,000

See TRANSMISSION under MISCELLANEOUS CONTROLS.
Transmission Speed Sensor (A/T Models)
See TRANSMISSION under MISCELLANEOUS CONTROLS.
Transmission Temperature Sensor (A/T Models)
See TRANSMISSION under MISCELLANEOUS CONTROLS.
Water-In-Fuel (WIF) Sensor
Water-in-fuel sensor is located in bottom of fuel
filter/water separator. Testing information not available from
manufacturer.
SWITCHES
Brake Switch
1) Remove lower panel for access to brake switch. Brake
switch is located on bracket, near top of brake pedal. Disconnect
electrical connector from brake switch. Pull plunger on brake switch
fully outward. See Fig. 2.
2) Using ohmmeter, check for continuity between terminals No.
5 and 6 on brake switch. See Fig. 2. Continuity should exist. If
continuity exists, go to next step. If continuity does not exist,
replace brake switch.
3) Push plunger on brake switch fully inward. Using ohmmeter,
check for continuity between terminals No. 1 and 2, and 3 and 4 on
brake switch. See Fig. 2. Continuity should exist. If continuity does
not exist, replace brake switch.
Fig. 2: Identifying Brake Switch Terminals
Courtesy of Chrysler Corp.
Park/Neutral Switch (A/T Models)
See TRANSMISSION under MISCELLANEOUS CONTROLS.

FUEL DELIVERY
Fuel Filter/Water Separator
1) A restricted fuel filter/water separator may cause engine
starting problems, prevent engine from accelerating, low power or
White exhaust smoke.
2) When ignition is first turned on, 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 tachometer.
3) 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.
4) Rotate handle on drain valve forward, toward front of
vehicle to DRAIN position. Drain valve is located near top of fuel
filter/water separator.
5) If no water exists and a clean flow of diesel fuel exists,
rotate handle on drain valve back to CLOSE position. Go to next step.
If water exists, allow water to drain until clean flow of diesel fuel
exists. Rotate handle on drain valve back to CLOSE position. Go to
next step.
6) Verify fuel filter/water separator has been serviced
according to proper service schedule. See SERVICE & ADJUSTMENT
SPECIFICATIONS - TRUCKS article. Ensure pre-filter was cleaned when
fuel filter/water separator was serviced. Pre-filter is located at
bottom of fuel heater on driver's side of engine. No other testing
information is available from manufacturer.
Fuel Heater
1) Malfunctioning fuel heater may cause excessive wax build-
up in fuel filter/water separator during cold ambient temperatures.
Wax build-up may cause hard starting, prevent engine from
accelerating, low power, or Blue or White smoke.
2) Disconnect electrical connector at fuel heater. Fuel
heater is located in top of fuel filter housing. Using ohmmeter, check
resistance between electrical terminals on fuel heater.
3) Resistance should be about one ohm when fuel is cold, and
about 1000 ohms when fuel is warm. Replace fuel heater if resistance
is not within specification.
NOTE: Fuel heater receives battery voltage from fuel heater relay.
Fuel heater relay is located in Power Distribution Center
(PDC), next to left battery. Refer to PDC lid for relay
location. For testing of fuel heater relay, see RELAYS under
RELAYS & SOLENOIDS. Consult wiring diagram for wiring circuit
testing. See appropriate wiring diagram in WIRING DIAGRAMS
article.
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.
Repair fuel supply line or fuel return line if restricted or leaking.
2) Check for fuel leaking from weep hole on housing of fuel
transfer pump. Replace fuel transfer pump if fuel is leaking from weep
hole. Check fuel transfer pump for output pressure, pressure drop,
supply restriction, and air leaks.
NOTE: Separate pressure tests are necessary because transfer pump
operates at 2 pressure cycles, depending on whether engine is
running or cranking.

Fuel Transfer Pump Output Pressure
1) Remove 2 existing filter plug fittings at top of fuel
filter housing. Install 2 spring-loaded one-way check valve fittings
at inlet and outlet port. Install Fuel Pressure Test Gauge (6828) to
inlet port fitting. Prevent engine from starting by removing fuel
injection pump relay. Relay is located in Power Distribution Center
(PDC) next to left battery. Relay location is notated on PDC lid.
2) Crank engine while observing fuel pressure test gauge.
Fuel pressure should be 5-7 psi (0.35-0.49 kg/cm

). Reinstall fuel
system relay to PDC. Start engine. Fuel pressure should be minimum of
10 psi (0.7 kg/cm

). Because fuel injection pump relay was removed, a
Diagnostic Trouble Code (DTC) may have been set. Use DRB scan tool to
erase DTC. Go to PRESSURE DROP test.
Pressure Drop
Turn engine off. Remove Fuel Pressure Test Gauge (6828) from
inlet port and attach to outlet port. Start engine and note fuel
pressure. Pressure should not be more than 5 psi (0.35 kg/cm

) less
than inlet port pressure in Fuel Transfer Pump Outlet Pressure test.
See FUEL TRANSFER PUMP OUTPUT PRESSURE test. If fuel pressure is not
to specification, replace fuel filter. Go to FUEL SUPPLY RESTRICTION
test.
NOTE: Following test requires use of DRB scan tool and Periphal
Expansion Port (PEP) module. Ensure transfer pump pressure is\
okay before performing following test.
Fuel Supply Restriction
1) Disconnect fuel supply line quick-connect fitting at left
rear side of engine compartment. After disconnecting fuel line,
plastic clip will remain attached to metal fuel line at engine. Remove
clip from metal line. Snap clip into fuel supply hose. Install Rubber
Adapter Hose (6631) into ends of disconnected fuel supply line.
2) Install transducer from PEP module to brass "T" fitting on
rubber adapter hose. Connect DRB scan tool to transducer. Start engine
and record vacuum reading with engine speed at wide open throttle.
3) If vacuum reading is less than 6 in. Hg, check for
restriction in fuel supply line or fuel tank module. Repair fuel
supply line or module for restrictions as necessary. Also check fuel
pump inlet filter at bottom of module for obstructions. Go to AIR LEAK
IN FUEL SUPPLY LINE test.
NOTE: Following test requires use of a 3-foot section of 1/4" I.D.
clear tubing and 1/8" fitting.
Air Leak In Fuel Supply Line
1) Locate 2 test port plug fittings at top of fuel filter
housing. Clean fitting area. Remove test port fitting at fuel inlet
side of housing toward rear of filter housing. Install 1/8" fitting
with 1/4" O.D. nipple in place of test port. Clamp clear tubing to
fitting nipple. Place other end of hose into clear container.
2) To put fuel transfer pump into a 25 second run mode, turn
ignition switch to CRANK position, then release back to RUN position
without starting engine. Wait for air to purge from empty hose before
checking whether air bubbles are present. If bubbles are present,
check for leaks in supply line to fuel tank. If supply line is not
leaking, remove fuel tank module. Remove filter at bottom of module.
Check for leaks between supply nipple at top of module and filter
opening at bottom of module. Replace module as necessary.
Overflow Valve
1) Clean area around overflow valve and fuel return line at
injection pump. Remove overflow valve from pump and banjo fitting.

See appropriate DTC P0505: IAC MOTOR CIRCUIT in SELF-
DIAGNOSTICS - JEEP, TRUCKS & RWD VANS article.
IGNITION SYSTEM
NOTE: For basic ignition checks, see TEST NS-SEL: NO START TEST
SELECTION in SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS
article.
EMISSION SYSTEMS & SUB-SYSTEMS
NOTE: To locate emission components, refer to emission control
information label in engine compartment.
AIR INJECTION
No Air Supply (Ram Pickup 5.9L & 8.0L)
1) Start engine, and increase engine speed to 1500 RPM. Check
air supply at rubber hoses. If air supply increases with RPM, air pump
operation is okay.
2) If air pump is okay, check for leakage at hoses and
fittings. Repair or replace hoses as necessary.
3) If hoses are okay, check pressure relief valve for
leakage. If air is expelled through pressure relief valve at idle,
replace relief valve.
4) If relief valve is okay on 5.9L, test is complete. On 8.
0L, check inlet air filter. Repair air filter if plugged. If air
filter is okay, test is complete.
CRANKCASE VENTILATION (CCV)
8.0L
1) CCV system does NOT use a PCV valve. System consists of a
fixed orifice (Gray color) that is calibrated to a specific flow rate.\
The fixed orifice (located on intake manifold) is connected by a tube
to right valve cover.
2) A similar orifice is used on left cylinder head, but is
Black in color and cannot be interchanged with Gray orifice. Ensure
orifice, tubes and fittings are clean and in good condition. No
further information is available from manufacturer.
EXHAUST GAS RECIRCULATION (EGR)
EGR Valve
See TEST NTC-2: CHECKING EGR SYSTEM in SELF-DIAGNOSTICS -
JEEP, TRUCKS & RWD VANS article.
FUEL EVAPORATION
EVAP Canister
EVAP canister is located in engine compartment. Canister has
no moving parts. Check for loose, missing, cracked or broken
connections and parts. Repair or replace as necessary. No liquid
should be in canister.
LEAK DETECTION PUMP (LDP)
LDP
See appropriate DTC P1494: LEAK DETECTION PUMP SWITCH OR
MECHANICAL FAULT test in SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS


H - T E STS W /O C O DES - D IE SEL

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Trouble Shooting - No Codes - Diesel
Ram Pickup
INTRODUCTION
Before using this article, perform steps in BASIC DIAGNOSTIC
PROCEDURES - TRUCKS - DIESEL and SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD
VANS articles. Use this article to diagnose driveability problems
existing when a hard Diagnostic Trouble Code (FTC) is not present.
NOTE: Some driveability problems may have been corrected by
manufacturer with a revised Powertrain Control Module (PCM).
Check with manufacturer for latest PCM application.
Symptom checks direct the technician to malfunctioning
component(s) for further diagnosis. A symptom should lead to a
specific component, system test or adjustment.
Use TEST PROCEDURES under INTERMITTENTS to locate
driveability problems that DO NOT occur when the vehicle is being
tested. These test procedures should also be used if an intermittent
(soft) FTC was present, but no problem is found during self-diagnostic\
testing.
NOTE: For specific testing procedures, see SELF-DIAGNOSTICS -
JEEP, TRUCKS & RWD VANS article. For specifications, see ON
-VEHICLE ADJUSTMENTS - TRUCKS - DIESEL or SERVICE &
ADJUSTMENT SPECIFICATIONS - TRUCKS article.
SYMPTOMS
SYMPTOM DIAGNOSIS
Symptom checks cannot be used properly unless the problem
occurs while the vehicle is being tested. To reduce diagnostic time,
ensure steps in BASIC DIAGNOSTIC PROCEDURES - TRUCKS - DIESEL and
SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS articles were performed
before diagnosing a symptom. Symptoms available for diagnosis are as
follows:
* Black Exhaust Smoke
* White Exhaust Smoke
* Blue Exhaust Smoke
BLACK EXHAUST SMOKE
* Air filter dirty or plugged:
* Air intake system restricted:
* Exhaust system restriction is above specification:
* Poor fuel quality:
* Fuel injection pump malfunctioning:
* Fuel injector malfunctioning or leaking:
* Fuel return system restricted:
* Intake manifold restricted:
* Turbocharger problem.
WHITE EXHAUST SMOKE

* Air in fuel system:
* Coolant leak into combustion chamber:
* Block heater malfunction in cold weather:
* Clogged or defective fuel filter:
* Poor fuel quality:
* Fuel injector malfunctioning or loose:
* Restricted or blocked fuel injection or supply lines:
* Intake/exhaust valves not adjusted properly (tight):
* Intake heaters malfunctioning:
* Internal engine damage.
BLUE EXHAUST SMOKE
* Air filter dirty or plugged:
* Air intake system restricted:
* Air leak in intake between turbocharger and intake
manifold:
* Restricted exhaust:
* Restricted turbocharger drain tube:
* Crankcase ventilation plugged:
* Valve stems, guides or seals worn or defective:
* Piston rings improperly gapped, worn or broken:
* Internal engine wear:
* Turbocharger failure.
INTERMITTENTS
INTERMITTENT PROBLEM DIAGNOSIS
Intermittent fault testing requires duplicating circuit or
component failure to identify problem. These procedures may lead to
PCM setting a Diagnostic Trouble Code (FTC) which may help in
diagnosis.
If problem vehicle does not produce DTCs, monitor voltage or
resistance values using a Digital Volt-Ohmmeter (DVOM) while
attempting to reproduce conditions causing intermittent fault. A
status change on DVOM indicates a fault has been located.
Use a DVOM to pinpoint faults. When monitoring voltage,
ensure ignition switch is in ON position or engine is running. Ensure
ignition switch is in OFF position or negative battery cable is
disconnected when monitoring circuit resistance. Status changes on
DVOM during test procedures indicate area of fault.
TEST PROCEDURES
Intermittent Simulation
To reproduce conditions creating an intermittent fault, use
following methods:
* Lightly vibrate component
* Heat component
* Wiggle or bend wiring harness
* Spray component with water
* Remove/apply vacuum source
Monitor circuit/component voltage or resistance while
simulating intermittent. If engine is running, monitor for diagnostic
trouble codes. Use test results to identify a faulty component or
circuit.

manifold, sends input signal to Engine Control Module (ECM). ECM uses
input signal for controlling fuel control, timing and engine
protection. ECM will lower engine power if boost is too high.
Oil Pressure Sensor
Oil pressure sensor signal is input to Engine Control Module
(ECM). ECM converts signal to pressure value. Value is sent on CCD Bus\
to instrument panel gauge/light. Oil pressure sensor is located on
side of engine block, below ECM. See Fig. 2.
Power Take Off (PTO)
This input is used on vehicles equipped with a Power Take Off
(PTO) unit. When PTO is engaged, Engine Control Module (ECM) will
disable some OBD-II functions.
Water-In-Fuel (WIF) Sensor
WIF sensor is located in bottom of fuel filter/water
separator. See Fig. 2. WIF sensor delivers input signal to Engine
Control Module (ECM) when water exists in the fuel filter/water
separator. As water level increases, resistance across WIF sensor
decreases. ECM compares decrease in resistance to a high water
standard value. When resistance is 30,000-40,000 ohms, ECM will turn
on WATER-IN-FUEL warning light. WATER-IN-FUEL warning light is located
on instrument panel, just below tachometer. ECM monitors input signal
when ignition switch is in the ON position and continues to monitor
input signal until intake manifold air heater post-heat cycle is
complete.
PCM INPUT SIGNALS
A/C Switch
When A/C switch is in ON position, an input signal is
delivered from A/C switch to Engine Control Module (ECM) to indicate
that A/C operation has been requested. Once A/C operation has been
requested, an A/C request signal is delivered to ECM from A/C high-
pressure switch and A/C low-pressure switch. The A/C request signal
indicates evaporator pressure is within proper range for A/C
operation. ECM uses A/C request signal to cycle A/C compressor clutch
by using an A/C clutch relay. A/C clutch relay may also be referred to
as A/C compressor clutch relay. If A/C high-pressure switch or A/C
low-pressure switch opens, A/C request signal will not be delivered to
the ECM. ECM will then open ground circuit for A/C clutch relay and
A/C compressor clutch will be disengaged.
The A/C clutch relay is located in power distribution center
at driver's side front corner of engine compartment, near the battery.
The A/C high-pressure switch is located on discharge line, near A/C
compressor. The A/C low-pressure switch is located on top of
accumulator.
Accelerator Pedal Position Sensor (APPS) Output From ECM
Accelerator Pedal Position Sensor (APPS) is mounted on top
left of engine. See Fig. 2. Sensor provides DC voltage input signal to
Engine Control Module (ECM) to indicate throttle position. On previous\
engines, there were linkages between accelerator pedal, throttle
position sensor and injection pump. On this engine, no linkage exists
between accelerator pedal and injection pump. APPS signal is sent on
CCD Bus circuit from ECM to PCM.
Automatic Shutdown (ASD) Relay
A 12-volt input signal is delivered from ASD relay to Engine
Control Module (ECM) when ASD relay is energized. If ECM does not
receive a 12-volt input signal when ASD relay is energized, a
Diagnostic Trouble Code (FTC) will be stored in ECM. ASD relay is