1999 DODGE RAM battery

Fig. 6: Intake Manifold Bolt Tightening Sequence (5.2L & 5.9L)
Courtesy of Chrysler Corp.
EXHAUST MANIFOLD
Removal
Disconnect negative battery cable. Raise and support vehicle.
Disconnect exhaust pipe from exhaust manifold. Lower vehicle. Remove
exhaust heat shields (if equipped). Remove bolts, nuts, washers and
exhaust manifold. Note location of conical washer on bolts/studs.
Remove manifold.
Inspection
Check exhaust manifold mating surface warpage. On 3.9L or 5.
2L, repair or replace exhaust manifold if warpage exceeds .004" (.10
mm) overall. On 5.9L applications, repair or replace exhaust manifold
if warpage exceeds .008" (.20 mm) per 12" (305 mm).

CAUTION: Install NEW studs in cylinder head if studs came out when
removing exhaust manifold. Apply sealant to coarse threads of
studs before installing in head.
Installation
To install, reverse removal procedure. Ensure conical washers
are installed in original locations. Tighten bolts/nuts to
specification, starting at center and working outward. See TORQUE
SPECIFICATIONS table.
CYLINDER HEAD
Removal
1) On Van, remove engine cover and heat shields. On all
models, disconnect battery, and drain coolant. Remove generator
bracket support rod and generator. Remove intake and exhaust manifold.
See INTAKE MANIFOLD and EXHAUST MANIFOLD.
2) Remove rocker arms and push rods. See ROCKER ARMS. Remove
cylinder head bolts, cylinder head and gasket.
Inspection
Check cylinder head warpage. Repair or replace cylinder head
if warpage exceeds specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS.
Installation
To install, reverse removal procedure. Tighten cylinder head
bolts, to specification and in sequence, using 3 steps. See Fig. 7.
See TORQUE SPECIFICATIONS table.
Fig. 7: Cylinder Head Bolt Tightening Sequence
Courtesy of Chrysler Corp.
FRONT COVER OIL SEAL

Removal
Disconnect negative battery cable. Remove drive belts from
crankshaft pulley. Remove fan and shroud. Remove crankshaft pulley and
vibration damper. Pry oil seal from front cover.
Installation
1) Use Seal Installer (6635) for seal installation. Installe\
r
should fit with minimum interference. If installer does not fit, front
cover must be removed and installed properly.
2) Position small diameter of oil seal over seal installer.
Using vibration damper bolt, tighten seal installer to draw seal into
position. Remove vibration damper bolt and seal installer. To complete
installation, reverse removal procedure.
FRONT COVER
Removal
1) Disconnect battery. Drain coolant. Remove power steering
pump (if equipped). Remove water pump. See WATER PUMP.
2) Remove crankshaft pulley and vibration damper. Loosen oil
pan bolts. Remove oil pan-to-front cover bolts on each side of oil
pan. Remove bolts, front cover and gasket. DO not damage oil pan
gasket.
Installation
1) Ensure sealing surfaces are clean. Apply a 1/8" (3.17 mm)\
bead of RTV sealant to oil pan gasket. Install gasket, front cover and
bolts. DO NOT tighten bolts at this time.
2) Install front cover oil seal. See FRONT COVER OIL SEAL.
Tighten front cover, oil pan and then vibration damper bolts to
specification. See TORQUE SPECIFICATIONS table. To complete
installation, reverse removal procedure.
TIMING CHAIN
Inspection
1) Remove front cover. See FRONT COVER. Position ruler at
camshaft sprocket, near timing chain link, to check timing chain
stretch.
NOTE: When applying torque to camshaft sprocket bolt, DO NOT allow
crankshaft to move. It may be necessary to hold crankshaft.
2) Place torque wrench on camshaft sprocket bolt. Apply 30
ft. lbs. (41 N.m) torque with cylinder heads installed, or 15 ft. lbs.\
(20 N.m) with cylinder heads removed, on camshaft sprocket bolt in
direction of engine rotation. Note reading on ruler.
3) Apply same amount of torque in opposite direction and note
amount of timing chain movement on ruler. If movement exceeds 1/8" (3.
17 mm), replace timing chain.
Removal
Rotate crankshaft so timing marks are aligned. See Fig. 8.
Remove camshaft sprocket bolt, camshaft sprocket, timing chain and
crankshaft sprocket.
Installation
1) Install timing chain and sprockets. Ensure timing marks
are aligned. See Fig. 8. Install camshaft sprocket bolt and tighten to
specification. See TORQUE SPECIFICATIONS table.
2) Ensure camshaft end play is within specification. See
CAMSHAFT table under ENGINE SPECIFICATIONS. If end play is not within
specification, replace thrust plate located between camshaft sprocket

CAUTION: After removing fan clutch assembly, DO NOT store fan clutch
with rear of shaft pointing downward. Silicone fluid from fan
clutch may drain into fan drive bearing, causing lubricant
failure.
Removal
1) Disconnect negative battery cable. Drain cooling system.
Remove throttle cable at top of fan shroud. Unsnap coolant overflow
tank from fan shroud and lay aside. DO NOT disconnect coolant hose.
2) Remove upper radiator hose. Using Fan Wrench (SP346) from\
Set (2017DSP), remove fan clutch assembly from water pump by turning
nut counterclockwise as viewed from front. DO NOT remove fan clutch
assembly at this time.
3) Remove fan shroud bolts and clips. Remove fan shroud and
fan clutch assembly as a unit. Locate accessory drive belt tensioner,
and rotate tensioner clockwise (counterclockwise on heavy-duty cycle
engines) to release tension on accessory drive belt.
4) Note drive belt routing for installation reference. Belt
must be correctly routed during installation, or engine will overheat
due to water pump rotating in wrong direction.
5) Remove bolts and water pump pulley. Disconnect lower
radiator hose and heater hoses. Remove coolant return tube from water
pump. Remove bolts, water pump and gasket.
Installation
To install, reverse removal procedure using NEW gasket.
Tighten bolts to specification. See TORQUE SPECIFICATIONS table. Fill
system with coolant. Ensure accessory drive belt is installed in
original direction to ensure proper rotation of water pump. See
Fig. 12 .
Fig. 12: Drive Belt Routing (Except 5.9L - Heavy Duty Cycle)
Courtesy of Chrysler Corp.

Fig. 13: Drive Belt Routing (5.9L - Heavy Duty Cycle)
Courtesy of Chrysler Corp.
OIL PAN
Removal (Dakota 2WD & Durango 2WD)
1) Disconnect negative battery cable. Remove oil dipstick and
distributor cap. Raise and support vehicle. Drain engine oil.
2) Remove exhaust pipe. Remove side engine mount bolts.
Slightly raise engine. When engine is at adequate height, install
bolts in side engine mount-to-frame bracket holes to support engine.
3) Lower engine, and allow it to rest on bolts installed in
side engine mounts. Remove oil pan bolts, oil pan and gaskets.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
where oil pan side gaskets meet end seals, and where end seals contact
cylinder block. See Fig. 14.
2) To facilitate oil pan installation, fabricate 4 alignment
dowels from 1 1/2" x 5/16" bolts. See Fig. 15. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table. To install remaining

components, reverse removal procedure.
Removal (Dakota 4WD & Durango 4WD)
1) Disconnect negative battery cable. Remove oil dipstick.
Drain engine oil. Remove exhaust pipe crossover and lower transmission
cover.
2) Remove front drive axle for access to oil pan. For front
drive axle removal, loosen wheel lug nuts. Remove cotter pin, lock nut
and spring washer. Loosen axle shaft nut with vehicle on floor and
brakes applied. Raise and support vehicle.
CAUTION: DO NOT pull on rubber boot during axle shaft removal. Pull on
outer CV joint only.
3) Remove wheels and skid plate. Remove axle shaft nut.
Remove axle shaft-to-differential flange bolts at front drive axle.
Support axle shaft, and separate axle splines from wheel hub by
pulling inward at outer CV joint.
4) Remove remaining axle shaft. Mark front drive shaft and
transfer case yoke for installation reference. Remove front drive
shaft from transfer case. Disconnect vacuum hoses from shift motor and
electrical connections at shift indicator switch.
5) Support front drive axle using a floor jack. Remove front
drive axle and shift motor bolts. Lower floor jack, and remove front
drive axle with drive shaft. Remove transmission lower cover. Remove
bolts, oil pan and gasket.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
oil pan side gaskets meet end seals and end seals contact cylinder
block. See Fig. 14.
2) To facilitate oil pan installation, fabricate 4 alignment
dowels from 1 1/2" x 5/16" bolts. See Fig. 15. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table.
3) To install remaining components, reverse removal
procedure. When installing front drive axle, loosely install all bolts
before tightening to specification. Tighten axle shaft nut to
specification with vehicle on ground. See TORQUE SPECIFICATIONS table.
Ensure reference marks on transfer case yoke and front drive shaft are
aligned.
Removal (Ram Pickup & Ram Van/Wagon - 3.9L)
1) Disconnect negative battery cable. Remove oil dipstick. On
Ram Van/Wagon, remove engine cover. On all models, remove air cleaner
and engine controller. Raise and support vehicle. Drain engine oil.
2) Remove left engine-to-transmission strut. Loosen exhaust
pipe support bracket. Disconnect exhaust pipe. On Ram Pickup, remove
oil pan and gasket.
3) On Ram Van/Wagon, remove starter, transmission dust
shield, oxygen sensor and air injection tube. On all models, remove
right engine mount nut. Loosen, but DO NOT remove, left engine mount
nut.
4) Support right side of engine using jackstand. Remove
transmission mount through-bolt, and support transmission using
jackstand. Raise engine and transmission enough for oil pan removal.
Remove bolts, oil pan and gasket.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
oil pan side gaskets meet end seals and end seals contact cylinder
block. See Fig. 14.

2) To facilitate oil pan installation, fabricate 4 alignment
dowels from 1 1/2" x 5/16" bolts. See Fig. 15. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table. To install remaining
components, reverse removal procedure. Tighten bolts to specification.
See TORQUE SPECIFICATIONS table. To install remaining components,
reverse removal procedure.
Removal (Ram Pickup & Ram Van/Wagon - 5.2L & 5.9L)
Disconnect negative battery cable. Remove oil dipstick. Raise
and support vehicle. Drain engine oil. Remove exhaust pipe. Remove
left engine-to-transmission strut. Remove bolts, oil pan and gasket.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
oil pan side gaskets meet end seals and end seals contact cylinder
block. See Fig. 14.
2) To facilitate oil pan installation, fabricate 4 alignment
dowels from 1 1/2" x 5/16" bolts. See Fig. 15. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table. To install remaining
components, reverse removal procedure.
Removal (Grand Cherokee)
Disconnect negative battery cable. Remove oil dipstick. Raise
and support vehicle. Drain engine oil. Disconnect O2 sensor. Remove
exhaust pipe and starter. Remove left engine-to-transmission strut.
Disconnect oil level sensor (if equipped). Remove bolts, oil pan and
gasket. DO NOT damage oil level sensor.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
oil pan side gaskets meet end seals and end seals contact cylinder
block. See Fig. 14.
2) To facilitate oil pan installation on all models,
fabricate 4 alignment dowels from 1 1/2" x 5/16" bolts. See Fig. 15.
Tighten bolts to specification. See TORQUE SPECIFICATIONS table. To
install remaining components, reverse removal procedure.
Fig. 14: Applying Sealant On Oil Pan Sealing Surfaces
Courtesy of Chrysler Corp.


* E N G IN E S YSTE M S U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 999 D odge P ic ku p R 1500
GENERAL INFORMATION
Engine Performance and Maintenance Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
Engine Assemblies
CYLINDER HEAD ASSEMBLIES
LONG BLOCK ASSEMBLIES
SHORT BLOCK ASSEMBLIES
Engine Components
ACCELERATOR PEDAL POSITION SENSORS
ACCESSORY BELTS
ACCESSORY PULLEYS
ACTUATORS
AIR CONDITIONING CYCLING SWITCHES
AIR CONDITIONING PRESSURE SENSORS
AIR DUCTS AND TUBES
AIR FILTER ELEMENTS
AIR FILTER GASKETS
AIR FILTER HOUSINGS AND GASKETS
AIR FUEL RATIO SENSORS
AIR INJECTION CONTROL SOLENOIDS
AIR PLENUMS
AIR PUMP BELTS
AIR PUMPS (ELECTRIC-DRIVEN)
AIR TUBES
ASPIRATOR, CHECK AND DECEL VALVES
BAFFLES
BALLAST PRIMARY SUPPLY RESISTOR WIRES
BALLAST RESISTORS AND PRIMARY SUPPLY RESISTOR WIRES
BAROMETRIC PRESSURE SENSORS
BATTERIES
BATTERY CABLES, WIRES AND CONNECTORS
BATTERY CONNECTORS
BATTERY TRAYS AND HOLD DOWN HARDWARE
BATTERY WIRES
BELT-DRIVEN AIR PUMPS
BELT IDLER ASSEMBLIES (ACCESSORY AND CAM BELTS)
BELT TENSIONERS (ACCESSORY AND CAM BELTS)
BOOST CONTROL MECHANISMS
CAMSHAFT POSITION SENSORS
CARBURETORS AND CHOKES
CASTING CORE PLUGS AND EXPANSION PLUGS
CHARGE AIR COOLERS "INTERCOOLERS" (CAC)
CHECK VALVES
CHOKES