1999 DODGE RAM Ignition system

120,000 MILE (204,000 KM)/96 MONTH NORMAL SERVICE
120,000 MILE (204,000 KM)/96 MONTH NORMAL SERVICE
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VERIFY 

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Last Major Service Was Performed. 

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INSPECT 

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 Exhaust System 


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 Brake Hoses 


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 Engine Coolant Level, Hoses & Clamps 


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 PCV Valve 

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SERVICE 

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 Rotate Tires 


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 Lubricate Steering Linkage 

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REPLACE 

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 Engine Oil 


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 Engine Oil Filter 


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 Air Cleaner Filter 


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 Spark Plugs 


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 Ignition Cables 

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LUBRICATION SPECIFICATIONS 

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Material  Condition  Specification 

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Engine Oil Ambient Temperature Above 0 F SAE 10W-30 

(
1)  (-18C) To Over 100F (38C)  


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Ambient Temperature Less Than  SAE 5W-30 

-20F (-29C) Up To 32F (0C) 

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Engine  All  50/50 Mixture Of 

Coolant   Distilled Water & 

  Ethylene Glycol 

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Brake Fluid  All  DOT 3 

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Steering  All  Mopar Multi-Mileage 

Linkage   Lubricant 

Lubricant   

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(
1) - SAE 10W-30 engine oil is preferred. Use only API approved 

oil with Starburst Symbol. 

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FLUID CAPACITIES 

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Item  Condition  Specification (1) 

SC HED ULE D S ER VIC ES
 


INSPECT 



 Exhaust System 




 Brake Hoses 




 Engine Coolant Level, Hoses & Clamps 




 Engine Air Cleaner & Air Pump Filters 




 Brake Linings 




SERVICE 



 Lubricate Steering Linkage 




 Automatic Transmission Bands 




 Clean EGR Passages (5.9L) 




REPLACE 



 Engine Oil 




 Engine Oil Filter (
1) 




 Automatic Transmission Fluid & Filter 




 Rear Axle Fluid 




 Front Axle Fluid (4x4) 




 Spark Plugs 




 Ignition Cables 




 PCV Valve (5.9L) 




 EGR Valve (5.9L) 




 Distributor Cap & Rotor (5.9L) 



(
1)  8.0L: Change oil filter at every oil change. 

5.9L: If mileage is less than 6,000 miles (9,600 Km) Yearly, 

replace the oil filter at every oil change. 




LUBRICATION SPECIFICATIONS 




Material  Condition  Specification 





Engine Oil Ambient Temperature Above 0 F SAE 10W-30 

(
1)  (-18C) To Over 100F (38C)  





Ambient Temperature Less Than  SAE 5W-30 

-20F (-29C) Up To 32F (0C) 





Engine  All  50/50 Mixture Of 

Coolant   Distilled Water & 

  Ethylene Glycol 





Brake Fluid  All  DOT 3 





2.4L ............................. 170-225 psi (11.9-15.7 kg/cm)
3.0L ...................................... 178 psi (12.5 kg/cm)
3.3L ........................................................ ( 1)
Minimum Compression Pressure
Caravan, Town & Country, & Voyager .......... 100 psi (7.0 kg/cm
)
Dakota
2.5L ........................................................ ( 1)
3.9L, 5.2L & 5.9L .......................... 100 psi (7.0 kg/cm
)
Durango ..................................... 100 psi (7.0 kg/cm)
Ram Pickup
3.9L, 5.2L & 5.9L (Gasoline) & 8.0L ........ 100 psi (7.0 kg/cm
)
5.9L (Diesel) ............................................... ( 1)
Ram Van & Ram Wagon ......................... 100 psi (7.0 kg/cm
)
Maximum Variation Between Cylinders
Caravan, Town & Country & Voyager ..................... 25 Percent
Dakota
2.5L ........................................ 30 psi (2.1 kg/cm
)
3.9L, 5.2L & 5.9L ........................................... ( 1)
Durango ...................................................... ( 1)
Ram Pickup, Ram Van & Ram Wagon .............................. ( 1)
( 1) - Information is not available from manufacturer.









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VALVE CLEARANCE
Gasoline Models
All engines are equipped with hydraulic lifters. No
adjustments are required.
5.9L Diesel (Ram Pickup)
Valve adjustment is recommended every 150 months or 150,000
miles during normal service, every 135,000 miles during severe
service. Severe service is described as frequent short trip operation
of less than 5 miles, long periods of engine idling, trailer towing,
police, taxi, local delivery service, or operating in dusty or
excessively hot conditions. See VALVE CLEARANCE SPECIFICATIONS
(DIESEL) table.
VALVE CLEARANCE SPECIFICATIONS (DIESEL) ( 1)









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Application In. (mm)\
Intake Valve ............................................ .010 (.25)\
Exhaust Valve ........................................... .020 (.51)\
(1) - Adjust valves with engine temperature less than 140
F (60C).








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IGNITION SYSTEM
IGNITION COIL
IGNITION COIL RESISTANCE - Ohms @ 70-80F (21-27C)








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Application Primary Secondary
Caravan
2.4L
Diamond ( 1)( 2) ............... .53-.65 .......... 11,500-13,500
Weastec ( 1) .................. .45-.65 .......... 10,900-14,700
3.0L ............................. ( 3) ..................... ( 3)

Fig. 8: Firing Order 8.0L V10 (Ram Pickup)
IGNITION TIMING
NOTE: On all models, ignition timing is controlled by Powertrain
Control Module (PCM). Ignition timing is non-adjustable. DO
NOT attempt to adjust ignition timing.
NOTE: On Dakota 3.9L, 5.2L and 5.9L, Durango, Ram Pickup 3.9L, 5.2L
and 5.9L (gasoline), Ram Van and Ram Wagon, the distributor
can be checked for proper location. See FUEL SYSTEM
SYNCHRONIZATION under FUEL SYSTEM in ON-VEHICLE ADJUSTMENTS.
FUEL SYSTEM
FUEL PUMP (GASOLINE)
FUEL PUMP PERFORMANCE








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Application Pressure psi Min. Vol.
(kg/cm) In 7 Sec. Pts. (L)

STA R TE R

1999 D odge P ic ku p R 1500
1999 STARTING & CHARGING SYSTEMS
CHRY - Starters - Except Avenger & Sebring Coupe
Breeze, Caravan, Cirrus, Concorde, Dakota, Durango, Intrepid,
LHS, Neon, Ram Pickup, Ram Van, Ram Wagon, Sebring
Convertible, Stratus, Town & Country, Voyager, 300M
NOTE: For models not covered in this article, see STARTERS -
AVENGER, SEBRING COUPE & TALON article.
DESCRIPTION
Bosch, Melco and Mitsubishi starters use a planetary gear
train that transmits power from starter motor to pinion shaft. Six
permanent magnets (Bosch and Melco starters) or 4 permanent magnets
(Mitsubishi starters) are used, eliminating potential field wire-to-
frame short circuits.
Nippondenso starter is a 4-field, 4-brush, 12-volt motor with
a solenoid mounted within the housing. The unit has a 2-to-1 reduction
gear set in a die cast aluminum housing. Starter has serviceable gear
and clutch assembly only. If starter solenoid fails, entire starter
motor must be replaced.
All models use a starter relay in starter circuit between the
battery and starter solenoid terminal. Automatic Transmission (A/T)
equipped vehicles use a Park/Neutral Position (PNP) switch or a
Transmission Range (TR) sensor to provide ground path for the starter
relay. Manual Transmission (M/T) equipped vehicles use a clutch pedal
position switch to provide battery voltage from ignition switch to the
starter relay. See WIRING DIAGRAMS.
STARTER APPLICATIONS - CARS









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Model Type
Breeze & Stratus 2.0L ........................................ Bosch
Cirrus, Sebring Convertible & Stratus
2.4L ................................................. Nippondenso
2.5L ....................................................... Melco
Concorde, Intrepid, LHS & 300M
2.7L ....................................................... Melco
3.3L & 3.5L .......................................... Nippondenso
Neon ......................................................... Bosch









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STARTER APPLICATIONS - TRUCKS








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Model Type
Caravan, Town & Country, & Voyager ..................... Nippondenso
Dakota & Durango
2.5L .................................................. Mitsubishi
3.9L & 5.2L .......................................... Nippondenso
Ram Pickup, Ram Van & Ram Wagon ........................ Nippondenso









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TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION.

ON-VEHICLE TESTING
CAUTION: When battery is disconnected, vehicle computer and memory
systems may lose memory data. Driveability problems may exist
until computer systems have completed a relearn cycle. See
COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION
before disconnecting battery.
DISABLING/ENABLING IGNITION & FUEL SYSTEMS
WARNING: To prevent engine from starting while performing tests,
always disable ignition and fuel systems.
Disabling Ignition & Fuel Systems
Remove Automatic Shutdown Relay (ASD) located in Power
Distribution Center (PDC). Refer to PDC cover for proper relay
location. PDC is located in engine compartment. On 5.9L diesel
engines, also disconnect fuel shutdown solenoid connector. Solenoid is
located behind upper intake manifold. See appropriate SYSTEM &
COMPONENT TESTING article in ENGINE PERFORMANCE section.
Enabling Ignition & Fuel Systems
When testing and/or repairs have been completed, verify
battery condition. Recharge battery as necessary, after starter tests
have been completed. Disconnect all test equipment. Install ASD relay.
On 5.9L diesel engines, reconnect fuel shutdown relay connector. On
all models, start engine several times to verify malfunction has been
corrected.
CRANKING TEST
NOTE: Ensure engine is at normal operating temperature. High
viscosity oil, extreme cold temperatures, or tight engine
will increase amperage draw.
1) Using a battery load tester, connect positive and negative
leads to battery. Connect inductive ammeter pick-up to positive
battery cable. Disable ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS.
2) Ensure all lights and accessories are off. Place A/T in
Park position or M/T in Neutral position. Apply parking brake. Crank
engine and observe voltmeter reading. If voltage is more than 9.6
volts and cranking amperage draw is more than specified amps, proceed
to CIRCUIT RESISTANCE TESTS. See STARTER SPECIFICATIONS - CARS or
STARTER SPECIFICATIONS - TRUCKS.
3) If voltage is 12.5 volts or more and cranking amperage
draw is less than specified, check starter circuit components in the
following order:
starter solenoid, starter relay, starter relay circuit, park/neutral
position switch or transmission range sensor (A/T), clutch pedal
position switch (M/T), ignition switch, wiring harness and
connections.
CIRCUIT RESISTANCE TESTS
NOTE: If excessive resistance is not found in circuits being
tested, remove starter and proceed to BENCH TESTING.
Battery Connection Resistance Test
1) Disable vehicle ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS. A voltmeter accurate to
one tenth of a volt will be needed for the following tests.

2) Connect voltmeter positive lead to negative battery cable
clamp. Connect voltmeter negative lead to negative battery post. Crank
engine and observe voltmeter reading. If voltage is detected, repair
poor contact between cable clamp and post. Perform same procedure to
positive battery post and cable clamp.
Ground Connection Resistance Test
Connect voltmeter negative lead to negative battery post.
Connect voltmeter positive lead to engine block, near negative battery
cable grounding point. Crank engine and observe voltmeter reading. If
voltmeter reading indicates more than 0.2 volt, repair poor ground
connection or replace ground cable.
Starter Ground Connection Resistance Test
Connect voltmeter negative lead to negative battery post.
Connect voltmeter positive lead to starter housing. Crank engine and
observe voltmeter reading. If voltmeter reading indicates more than 0.
2 volt, repair poor starter-to-ground connection.
Positive Battery Cable Resistance Test
1) Remove starter heat shield (if equipped) to gain access t\
o
starter solenoid connections. Connect voltmeter negative lead to
starter solenoid battery terminal and voltmeter positive lead to
positive battery post.
2) Crank engine and observe voltmeter reading. If voltage
reads more than 0.2 volt, correct poor connection between battery
cable and starter solenoid or replace positive battery cable.
SOLENOID CIRCUIT TEST
NOTE: Perform SOLENOID CIRCUIT TEST before testing starter relay
and starter relay circuit. Ensure A/T is in Park position or
M/T is in Neutral position and parking brake is applied.
1) Disable vehicle ignition and fuel systems. See
DISABLING/ENABLING IGNITION & FUEL SYSTEMS.
2) Ensure battery is fully charged. Ensure solenoid
connections are not loose or corroded. Remove starter relay from Power
Distribution Center (PDC). Refer to PDC cover for proper relay
location. PDC is located in engine compartment.
3) Connect a remote starter switch or jumper wire between
starter relay socket terminal No. 87 and positive battery post. See
Fig. 1 or 2. If engine cranks, solenoid and starter are good. Go to
STARTER RELAY TEST.
4) If engine fails to crank, or if solenoid chatters, check
wiring and connectors from starter relay socket to starter solenoid
terminal. Repair any loose or corroded connections. If engine still
fails to crank, remove starter and proceed to SOLENOID TEST under
BENCH TESTING.
STARTER RELAY TEST
NOTE: Perform SOLENOID CIRCUIT TEST before testing starter relay.
Remove starter relay from Power Distribution Center (PDC).
Refer to PDC cover for proper relay location. PDC is located in engine
compartment. Connect 12-volt power source to starter relay terminal
No. 86 and ground terminal No. 85. See Fig. 1 or 2. Using ohmmeter,
check continuity across starter relay terminals No. 30 and 87. If
continuity is not present, replace starter relay.

STE ER IN G C O LU M N

1999 D odge P ic ku p R 1500
1998-99 STEERING
CHRY - Steering Columns - Trucks & Vans
Caravan, Dakota, Durango, Ram Pickup, Ram Van/Wagon,
Town & Country, Voyager
WARNING: All models are equipped with Air Bag Restraint System (ABRS).
See AIR BAG PRECAUTIONS before working on vehicle. Use
caution when working around steering column (air bag could
deploy).
CAUTION: When battery is disconnected, vehicle computer and memory
systems may lose memory data. Driveability problems may exist
until computer systems have completed a relearn cycle. See
COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION
before disconnecting battery.
DESCRIPTION & OPERATION
All models use collapsible steering columns with an integral
ignition switch and locking device. See Fig. 1. Optional tilt wheel is
available.
AIR BAG PRECAUTIONS
Follow precautions when working with air bag systems:
* When performing air bag repairs, disable ABRS. See AIR BAG
DISABLING.
* Use caution when handling a sensor. Never strike or jar a
sensor. All sensors or mounting bracket bolts must be
carefully torqued to ensure proper sensor operation.
* Never apply power to ABRS if a sensor is not rigidly attached
to vehicle.
* To avoid accidental air bag deployment while trouble shooting
ABRS, DO NOT use electrical test equipment, such as AC
-powered or battery-powered voltmeter, ohmmeter, etc.
* Always carry air bag module with trim cover away from body.
Always place inflatable module on workbench with trim cover
up, away from loose objects.
* DO NOT install used air bag parts from another vehicle. Use
NEW parts only. DO NOT disassemble or tamper with air bag
assembly.
* Wait at least 2 minutes after disconnecting battery before
proceeding with repairs or trouble shooting system. For a
short time after battery is disconnected, ABRS retains enough
voltage to deploy air bag.
NOTE: For additional information, see appropriate AIR BAG RESTRAINT
SYSTEMS article in ACCESSORIES & EQUIPMENT section.
AIR BAG DISABLING
Disconnect and isolate negative battery cable. Disconnect 2-
way yellow clockspring harness connector, located on top of fuse block
between clockspring and instrument panel wiring harness. Clockspring
connector may also be disconnected at Air Bag System Diagnostic Module
(ASDM).