1999 DODGE RAM engine

5) If PCM has not been replaced, and TEST VER-2A is being
performed after an A/C relay control circuit DTC test, ensure A/C is
on and go to next step.
6) Road test vehicle for at least 5 minutes. Road test
vehicle at a speed of at least 40 MPH at some point during road test.
Stop vehicle. Turn engine off for at least 10 seconds. Start engine
and continue road test. Ensure transmission shifts through all gears.
After road test, turn engine off and go to next step.
7) Using scan tool, read DTCs. If any DTC returns, perform
appropriate test(s). If no DTCs return, test is complete. Go to next
step.
8) Turn ignition on, with engine off. Using scan tool, erase
DTCs. Turn ignition off. Disconnect scan tool. Test is complete.
TEST VER-2A (DIESEL)
NOTE: If Accelerator Pedal Position Sensor (APPS), battery, Engine
Control Module (ECM) or Powertrain Control Module (PCM) has\
been disconnected or replaced, APPS must be reprogrammed and
correct vehicle mileage and Vehicle Identification Number
(VIN) must be programmed into PCM to prevent Diagnostic
Trouble Codes (DTCs) from being set in Anti-Lock Brake System\
(ABS) module and Supplemental Restraint System (SRS) module\
.
To program PCM and clear DTCs from ABS and SRS modules,
proceed to appropriate procedure listed below. On models
equipped with a Smart Key Immobilizer Module (SKIM), if
replacing Powertrain Control Module (PCM), secret key data
must also be updated to enable engine starting. To update
secret key data, proceed to appropriate procedure listed
below.
CAUTION: DO NOT attempt to adjust screws or disassemble APPS. Settings
are preset at factory and are not intended to by changed.
Procedure For Programming APPS
Reassemble all components. Turn ignition switch to ON or RUN
position without starting engine. Slowly press accelerator pedal to
floor once and slowly release. This procedure programs APPS
calibration in ECM. Go to step 1)).
Procedure For Programming PCM & Clearing DTCs From ABS & SRS
Modules
Connect scan tool to Data Link Connector (DLC). Using scan
tool, enter correct VIN and mileage into PCM. Using scan tool
manufacturer's instructions, clear DTCs from ABS and SRS modules. Go
to step 1)).
Procedure For Updating Secret Key Data
Connect scan tool to Data Link Connector (DLC). Go to ENGINE
and then MISC menus on scan tool. Place SKIM in SECURED ACCESS MODE by
using appropriate Personal Identification Number (PIN) for this
vehicle. PIN may be obtained from owner, vehicle's invoice, or from
manufacturer. Select UPDATE THE SECRET KEY DATA. Data will be
transferred from Smart Key Immobilizer Module (SKIM) to PCM. Go to
step 1)).
1) If PCM has not been replaced, and TEST VER-2A (DIESEL) is\
being performed after a No Trouble Code (NTC) test, inspect vehicle to\
ensure all engine components are connected. Reassemble and reconnect
components as necessary. Check if initial symptom still exists. If
initial symptom exists, check for Technical Service Bulletins (TSBs)
that apply to vehicle and see TEST NTC-1A: NO TROUBLE CODE TEST MENU
in ENGINE PERFORMANCE, or appropriate TROUBLE SHOOTING - NO CODES

article in ENGINE PERFORMANCE for diagnosis by symptom. If initial
symptom no longer exists, test is complete. Go to step 6).
2) If PCM has not been replaced, and TEST VER-2A (DIESEL) is\
being performed after a DTC test, inspect vehicle to ensure all engine
components are connected. Reassemble and reconnect components as
necessary. Using scan tool, erase DTCs, reset all memory values and go
to step 4).
3) If PCM has not been replaced, and TEST VER-2A (DIESEL) is\
being performed after an A/C relay control circuit DTC test, ensure
A/C is on and go to next step.
4) Road test vehicle for at least 5 minutes. Road test
vehicle at a speed of at least 40 MPH at some point during road test.
Stop vehicle. Turn engine off for at least 10 seconds. Start engine
and continue road test. Ensure transmission shifts through all gears.
After road test, turn engine off and go to next step.
5) Using scan tool, read DTCs. If any DTC returns, perform
appropriate test(s). If no DTCs return, test is complete. Go to next
step.
6) Turn ignition on, with engine off. Using scan tool, erase
DTCs. Turn ignition off. Disconnect scan tool. Test is complete.
TEST VER-5A (EXCEPT DIESEL)
NOTE: If Powertrain Control Module (PCM) is replaced, correct
vehicle mileage and Vehicle Identification Number (VIN) must
be programmed into PCM to prevent Diagnostic Trouble Codes
(DTCs) from being set in Anti-Lock Brake System (ABS) modul\
e
and Supplemental Restraint System (SRS) module. To program
PCM and clear DTCs from ABS and SRS modules, proceed to
appropriate procedure listed below. On models equipped with a
Smart Key Immobilizer Module (SKIM), if replacing Powertrain
Control Module (PCM), secret key data must also be updated to\
enable engine starting. To update secret key data, proceed to
appropriate procedure listed below.
Procedure For Programming PCM & Clearing DTCs From ABS & SRS
Modules
Connect scan tool to Data Link Connector (DLC). Using scan
tool, enter correct VIN and mileage into PCM. Using scan tool
manufacturer's instructions, clear DTCs from ABS and SRS modules. Go
to step 1)).
Procedure For Updating Secret Key Data
Connect scan tool to Data Link Connector (DLC). Go to ENGINE
and then MISC menus on scan tool. Place SKIM in SECURED ACCESS MODE by
using appropriate Personal Identification Number (PIN) for this
vehicle. PIN may be obtained from owner, vehicle's invoice, or from
manufacturer. Select UPDATE THE SECRET KEY DATA. Data will be
transferred from Smart Key Immobilizer Module (SKIM) to PCM. Go to
step 1)).
1) Inspect vehicle to ensure all engine components are
connected. Reassemble and reconnect components as necessary. If any
DTCs have not been diagnosed, return to appropriate test(s). If all
DTCs have been diagnosed and repaired, go to next step.
2) Connect scan tool to Data Link Connector (DLC) if not
previously done. Ensure fuel tank is at least 1/4 full. Ensure A/C is
off. Go to next step.
3) Proper way to ensure DTC is repaired is to allow
Powertrain Control Module (PCM) to run monitor. Monitor operation may
be observed on scan tool. All specified enabling conditions for
specified DTC must be met before PCM will operate monitor. Go to next
step.

4) Using scan tool, monitor pretest enabling conditions until
all conditions have been met. Once all enabling conditions are met,
observe appropriate monitor for DTC on scan tool. If repaired DTC has
reset or is seen on monitor while on road test, repair is not
complete. Check for related Technical Service Bulletins (TSBs) and
return to appropriate test. If no DTCs return, test is complete. Go to
step 6).
5) If another DTC exists, return to appropriate test(s). If
no DTCs return, test is complete. Go to next step.
6) Turn ignition on, with engine off. Using scan tool, erase
DTCs. Turn ignition off. Disconnect scan tool. Test is complete.
TEST VER-5A (DIESEL)
NOTE: If Accelerator Pedal Position Sensor (APPS), battery, Engine
Control Module (ECM) or Powertrain Control Module (PCM) has\
been disconnected or replaced, APPS must be reprogrammed and
correct vehicle mileage and Vehicle Identification Number
(VIN) must be programmed into PCM to prevent Diagnostic
Trouble Codes (DTCs) from being set in Anti-Lock Brake System\
(ABS) module and Supplemental Restraint System (SRS) module\
.
To program PCM and clear DTCs from ABS and SRS modules,
proceed to appropriate procedure listed below. On models
equipped with a Smart Key Immobilizer Module (SKIM), if
replacing Powertrain Control Module (PCM), secret key data
must also be updated to enable engine starting. To update
secret key data, proceed to appropriate procedure listed
below.
CAUTION: DO NOT attempt to adjust screws or disassemble APPS. Settings
are preset at factory and are not intended to by changed.
Procedure For Programming APPS
Reassemble all components. Turn ignition switch to ON or RUN
position without starting engine. Slowly press accelerator pedal to
floor once and slowly release. This procedure programs APPS
calibration in ECM. Go to step 1)).
Procedure For Programming PCM & Clearing DTCs From ABS & SRS
Modules
Connect scan tool to Data Link Connector (DLC). Using scan
tool, enter correct VIN and mileage into PCM. Using scan tool
manufacturer's instructions, clear DTCs from ABS and SRS modules. Go
to step 1)).
Procedure For Updating Secret Key Data
Connect scan tool to Data Link Connector (DLC). Go to ENGINE
and then MISC menus on scan tool. Place SKIM in SECURED ACCESS MODE by
using appropriate Personal Identification Number (PIN) for this
vehicle. PIN may be obtained from owner, vehicle's invoice, or from
manufacturer. Select UPDATE THE SECRET KEY DATA. Data will be
transferred from Smart Key Immobilizer Module (SKIM) to PCM. Go to
step 1)).
1) If PCM has not been replaced, inspect vehicle to ensure
all engine components are connected. Reassemble and reconnect
components as necessary. If any DTCs have not been diagnosed, return
to appropriate test(s). If all DTCs have been diagnosed and repaired,
go to next step.
2) Ensure fuel tank is at least 1/4 full. Ensure A/C is off.
Proper way to ensure DTC is repaired is to connect scan tool to Data
Link Connector (DLC) and allow Powertrain Control Module (PCM) to ru\
n
a DTC SPECIFIC GOOD TRIP COUNTER for 2 minutes. If DTC SPECIFIC GOOD

TRIP COUNTER displays "0", return to appropriate test(s). If DTC
SPECIFIC GOOD TRIP COUNTER displays one or more, repair is complete.
Go to step 9).
3) If coming to this test from a mis-fire DTC test, go step
7). If coming to this test from other than a mis-fire DTC test, use
scan tool to monitor pretest enabling conditions until all conditions
have been met. Once all enabling conditions are met, observe
appropriate monitor for DTC on scan tool and go to next step.
4) Using scan tool, monitor SIMILAR CONDITIONS to attempt to
duplicate conditions that vehicle was operating at when DTC was set.
If conditions can be duplicated, GOOD TRIP COUNTER will change to one
or more. Monitor operation may be observed on scan tool. All specified
enabling conditions for specified DTC must be met before PCM will
operate monitor. Go to next step.
5) Turn ignition off for 10 seconds. Start engine and allow
it to idle for 2 minutes while monitoring scan tool. If STARTS SINCE
SET and DTC SPECIFIC GOOD TRIP COUNTER change to one or more, repair
is complete. Go to step 9). If STARTS SINCE SET and DTC SPECIFIC GOOD
TRIP COUNTER do not change to one or more, go to next step.
6) Using scan tool, read DTCs. If any DTC exists, return to
appropriate test(s). If no other DTC exists, go to next step.
7) Using scan tool, monitor SIMILAR CONDITIONS to attempt to
duplicate conditions that vehicle was operating at when DTC was set.
If conditions can be duplicated, MISFIRE GOOD TRIP COUNTER will change
to one or more. If MISFIRE GOOD TRIP COUNTER changes to one or more,
test is complete. Go to step 9). If MISFIRE GOOD TRIP COUNTER does not
change to one or more, go to next step.
8) Using scan tool, read DTCs. If any DTC exists, return to
appropriate test(s). If no other DTC exists, go to next step.
9) Turn ignition on, with engine off. Using scan tool, erase
DTCs. Turn ignition off. Disconnect scan tool. Test is complete.
REMOVAL & INSTALLATION
GOVERNOR PRESSURE SENSOR, GOVERNOR PRESSURE SOLENOID &
TRANSMISSION FLUID TEMPERATURE SENSOR
NOTE: Transmission fluid temperature sensor is integral with
governor pressure sensor.
Removal
1) Raise and support vehicle. Drain transmission fluid.
Remove transmission oil pan and filter. Disconnect harness connectors
from governor pressure solenoid and sensor.
2) Remove pressure solenoid retainer-to-governor body screws.
Separate solenoid retainer from governor and pull solenoid from
governor body.
3) Remove governor body-to-valve body bolts. Separate
governor body from valve body. Remove governor body and gasket. Remove
retainer clip holding pressure sensor to governor body and remove
pressure sensor.
Installation
1) Clean all gasket surfaces. Lubricate NEW "O" ring with ATF
and install on pressure sensor. Push pressure sensor into governor
body and install retainer clip. Position governor body on valve body
with NEW gasket and install governor body-to-valve body bolts.
2) Lubricate NEW "O" ring with ATF and install on pressure
solenoid. Push solenoid into governor body. Install solenoid retainer.
Reconnect harness connectors to pressure solenoid and sensor. To
complete installation, reverse removal procedure.


F - B ASIC T E STIN G - D IE SEL

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Basic Diagnostic Procedures - Trucks - Diesel
Ram Pickup
INTRODUCTION
The following diagnostic steps will help prevent overlooking
a simple problem. This is also where to begin diagnosis for a no-start
condition.
The first step in diagnosing any driveability problem is
verifying the customer's complaint with a test drive under the
conditions the problem reportedly occurred.
Before entering self-diagnostics, perform a careful and
complete visual inspection. Most engine control problems result from
mechanical breakdowns or poor electrical connections. Before
condemning the computerized system, perform each test listed in this
article.
Two different module systems are used for powertrain control
of diesel engine. The Engine Control Module (ECM), located on left
side of engine, is used to control the fuel system. See Fig. 1. The
Fuel Pump Control Module (FPCM) located on pump, is a separate
component of ECM.
The Powertrain Control Module (PCM), located at right rear of\
engine compartment, is used for charging system, transmission and
speed control functions. CCD Bus circuits connect the various vehicle
control modules. These circuits are connected between ECM and PCM to
allow communication between modules.
Fig. 1: Locating Fuel System & Various Engine Components
Courtesy of Chrysler Corp.
PRELIMINARY INSPECTION & ADJUSTMENTS

VISUAL INSPECTION
1) Check Water-In-Fuel (WIF) sensor electrical connector for\
corrosion, damaged terminals or wiring and tight fit on engine wiring
harness. WIF sensor is located in bottom of fuel filter/water
separator. See Fig. 1.
2) Check for water in fuel filter/water separator by placing
drain pan below drain tube at fuel filter/water separator. See Fig. 1.
3) With engine not running, 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. Drain
water from fuel filter/water separator.
4) 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.
5) Verify fuel filter/water separator has been serviced
according to proper service schedule. See SERVICE & ADJUSTMENT
SPECIFICATIONS - TRUCKS article.
6) Check color of Filter Minder. Filter Minder is located on
top cover on air filter housing, just above air filter. DO NOT remove
air filter from air filter housing for inspection. If Yellow disc in
Filter Minder has reached Red zone, remove and inspect air filter. See
Fig. 2 . If air filter is dirty, replace air filter and reset Filter
Minder by pressing rubber button on top of Filter Minder.
NOTE: The Yellow disc in Filter Minder may reach Red zone if air
intake is restricted or air filter has become wet during
heavy rain or snow. If air filter has become wet, allow air
filter to dry during normal engine operation and reset Filter
Minder by pressing rubber button on top of Filter Minder.
7) Ensure intercooler inlet and outlet duct clamps are tight
and front of intercooler is not restricted with dirt. See Fig. 3.
Fig. 2: Identifying Filter Minder Components
Courtesy of Chrysler Corp.

Fig. 3: Locating Intercooler & Components
Courtesy of Chrysler Corp.
8) Ensure connections on both batteries are tight and not
corroded. Ensure the three 32-pin connectors are fully engaged on
Powertrain Control Module (PCM). PCM is located on firewall at
passenger's side rear corner of engine compartment.
9) Check for loose, defective or corroded connections at
intake manifold air temperature sensor. See Fig. 4.
10) Ensure electrical connections on intake manifold air
heater relays and intake manifold air heater are tight and not
corroded. Intake manifold air heater relays are mounted on inner
wheelwell, below driver's side battery. See Fig. 5. Intake manifold
air heater is located between air inlet housing and intake manifold
cover. See Fig. 6.

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.