1999 DODGE RAM Ignition

Engine pre-oiling can be done using pressure oiler (if
available). Connect pressure oiler to cylinder block oil passage
such as oil pressure sending unit. Operate pressure oiler long enough
to ensure correct amount of oil has filled crankcase. Check oil level
while pre-oiling.
If pressure oiler is not available, disconnect ignition
system. Remove oil pressure sending unit and replace with oil pressure
test gauge. Using starter motor, rotate engine starter until gauge
shows normal oil pressure for several seconds. DO NOT crank engine
for more than 30 seconds to avoid starter motor damage.
Ensure oil pressure has reached the most distant point from
the oil pump. Reinstall oil pressure sending unit. Reconnect ignition
system.
INITIAL START-UP
Start the engine and operate engine at low speed while
checking for coolant, fuel and oil leaks. Stop engine. Recheck coolant
and oil level. Adjust if necessary.
CAMSHAFT
Break-in procedure is required when a new or reground
camshaft has been installed. Operate and maintain engine speed between
1500-2500 RPM for approximately 30 minutes. Procedure may vary due to
manufacturers recommendations.
PISTON RINGS
Piston rings require a break-in procedure to ensure seating
of rings to cylinder walls. Serious damage may occur to rings if
correct procedures are not followed.
Extremely high piston ring temperatures are produced obtained
during break-in process. If rings are exposed to excessively high RPM
or high cylinder pressures, ring damage can occur. Follow piston ring
manufacturer's recommended break-in procedure.
FINAL ADJUSTMENTS
Check or adjust ignition timing and dwell (if applicable).
Adjust valves (if necessary). Adjust carburetion or injection idle
speed and mixture. Retighten cylinder heads (if required). If
cylinder head or block is aluminum, retighten bolts when engine is
cold. Follow the engine manufacturer's recommended break-in procedure
and maintenance schedule for new engines.
NOTE: Some manufacturer's require that head bolts be retightened
after specified amount of operation. This must be done to
prevent head gasket failure.

FUEL TANKS
GAS CAPS
GASKETS
GROMMETS (VALVE COVER)
HARMONIC DAMPERS
HEATER CONTROL VALVES
HEATER CORES
HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS
HOSE CLAMPS
HOSE CONNECTORS
HOSE COUPLERS
HOSES AND TUBES (FUEL LINES, RADIATOR, VACUUM, BY PASS,
HEATER, RECOVERY TANK AND OIL COOLERS)
HOUSINGS
IDLE AIR CONTROLS
IDLE SPEED CONTROL ACTUATORS
IGNITION BOOTS
IGNITION COIL TOWERS
IGNITION COILS
IGNITION CONTROL MODULES (ICM)
IGNITION SWITCHES
IGNITION TERMINALS
IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY)
IN-TANK FUEL STRAINERS
INERTIA FUEL SHUT-OFF SWITCHES
INTAKE AIR TEMPERATURE SENSORS
INTAKE MANIFOLDS
INTERCOOLERS
KNOCK SENSORS
LIQUID VAPOR SEPARATORS
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORS
MASS AIR FLOW (MAF) SENSORS
METAL AIR MANIFOLDS AND PIPES
METAL AIR PIPES
MIX CONTROL SOLENOIDS
MOTOR MOUNTS
O-RINGS, GASKETS, SEALS AND SPRING LOCKS
O2 SENSORS
OIL PRESSURE SENDING UNITS
OIL PUMP PICK-UP SCREENS
OIL PUMPS
PARK NEUTRAL POSITION SWITCHES
PCV BREATHER ELEMENTS
PCV ORIFICES
PCV VALVES
PICK-UP ASSEMBLIES (INCLUDES MAGNETIC, HALL EFFECT AND
OPTICAL)
POWER STEERING PRESSURE SENSORS
POWERTRAIN CONTROL MODULES (PCM) AND PROM
POWERTRAIN CONTROL PROM
PRESSURIZED EXPANSION TANK CAPS
RADIATOR CAPS AND PRESSURIZED EXPANSION TANK CAPS
RADIATOR FAN BLADES
RADIATOR FAN CLUTCHES
RADIATORS
ROLL OVER VALVES
SEALING COMPOUNDS
SEALS
SECONDARY AIR INJECTION SYSTEM MANAGEMENT DEVICES
SENSORS AND ACTUATORS
SHROUDS, BAFFLES AND DEFLECTORS
SPARK PLUGS
SPRING LOCKS

Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... (1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
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) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Determine source of contamination, such as engine coolant,
fuel, metal particles, or water. Require repair or
replacement.
( 3) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable;
check for accepted cleaning procedure.









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IGNITION BOOTS
See
IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY) .
IGNITION COIL TOWERS
See
IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY) .
IGNITION COILS
IGNITION COIL INSPECTION








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Condition Code Procedure
Arcing .................. A ............ Require replacement.
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.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or

replacement.
Connector missing ....... C ............ Require replacement.
Corroded, affecting
performance ............ A ............ Require replacement.
Corroded, not affecting
performance ............ 2 ............ Suggest replacement.
Distorted ............... .. .... (2) No service suggested or
required.
Inoperative ............. A ........ ( 3) Require replacement.
Oil leaking ............. A ............ Require replacement.
Out of specification .... B ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
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) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Distortion may be the result of overheating; coil should
be tested.
( 3) - Inoperative includes intermittent operation.









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IGNITION CONTROL MODULES (ICM)
IGNITION CONTROL MODULE (ICM) INSPECTION








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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of hardware.
Attaching hardware
threads stripped
(threads missing) ...... A ... Require repair or replacement
of hardware.
Code set
(if applicable) ........ A .......... ( 1) Further inspection
required.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 2) Require repair or
replacement.

Connector missing ....... A ................. Require repair.
Contaminated ............ A ........... (3) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Malfunctioning .......... A ........... ( 4) Require repair or
replacement.
Missing ................. C ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 2) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
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) - Includes inoperative, intermittent operation, or failure to
perform all functions.









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IGNITION SWITCHES
See SWITCHES.
IGNITION TERMINALS
See
IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY) .
IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY)
NOTE: You are not required to replace ignition wires in sets.
However, you may suggest replacement of the entire
secondary wire set for preventive maintenance.
IGNITION WIRE, BOOT, COIL TOWER AND TERMINAL (SECONDARY) INSPECTION









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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
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.
Carbon-tracked .......... A ............ Require replacement.
Corroded ................ 1 .. Suggest repair or replacement.
Insulation leaking
(shorted) .............. A .. Require repair or replacement.
Metal heat shield bent .. 2 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Oil-soaked (spongy) ..... 1 ............ Suggest replacement.
Resistance incorrect .... B ............ Require replacement.
Routed incorrectly ...... 2 ............. (1) Suggest repair.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 2) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
( 1) - If improper routing affects the performance of other
systems, require repair. Proper routing, hardware,
heatshields, etc., are intended to prevent premature
failure of secondary ignition components.
( 2) - Determine cause and correct prior to repair or
replacement of part.









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IN-TANK FUEL STRAINERS
IN-TANK FUEL STRAINER INSPECTION








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Condition Code Procedure
Missing ................. C ............ Require replacement.
Restricted .............. A .. Require repair or replacement.
Torn .................... A ............ Require replacement.









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INERTIA FUEL SHUT-OFF SWITCHES
INERTIA FUEL SHUT-OFF SWITCH 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

4) To install, reverse removal procedure. Ensure heater
housing top cover seal, firewall and side cowl seals are in good
condition.
Fig. 7: Removing Radiator Support Assembly (Ram Van/Wagon)
Courtesy of Chrysler Corp.
HEATER CONTROL PANEL R & I
Removal & Installation (Dakota & Durango)
1) Disconnect negative battery cable. On models equipped with
A/T, unlock ignition switch. Set parking brake and place gear selector
lever in "L" position. If equipped, set tilt steering column in lowest
position.
2) On all models, carefully pry bezel away from instrument
panel to disengage clips. Unplug connectors from cigarette lighter and
auxiliary power outlet. Disconnect fog light switch (if equipped).
Remove 4 heater control panel bolts.
3) Pull control panel outward enough to disconnect wiring
connector, vacuum harness and temperature control cable. Remove heater
control panel. To install, reverse removal procedure. Adjust
temperature control cable. See TEMPERATURE CONTROL CABLE ADJUSTMENT .
Removal & Installation (Ram Pickup)
1) Disconnect negative battery cable. Reach under driver's

side of instrument panel, near transmission tunnel, and unplug heater
control panel-to-heater assembly vacuum harness connector. Disconnect
vacuum harness from center air duct.
2) On models equipped with A/T, unlock ignition switch. Set
parking brake and place gear selector lever in "L" position. If
equipped, set tilt steering column in lowest position.
3) On all models, remove screw securing cluster bezel to
instrument panel. See Fig. 8. Carefully pry bezel away from instrument
panel to disengage clips. Unplug connectors from cigarette lighter and
auxiliary power outlet.
4) Remove 4 bolts attaching heater control panel. Pull
control panel outward enough to disconnect wiring connector and vacuum
harness. Remove heater control panel. To install, reverse removal
procedure.
Fig. 8: Removing Cluster Bezel (Ram Pickup)
Courtesy of Chrysler Corp.
CAUTION: Use care when removing or installing instrument cluster bezel
so as not to damage trip odometer reset button. If trip
odometer reset button is damaged, instrument cluster must be
replaced.
Removal & Installation (Ram Van/Wagon)
1) Disconnect negative battery cable. Remove engine cover
from passenger compartment. Reach between upper dash panel engine
housing extension and bottom of instrument panel. Disconnect vacuum
harness connector located near left defroster outlet of distribution
duct.
2) On models equipped with A/T, unlock ignition switch. Set
parking brake and place gear selector lever in "L" position. If
equipped, set tilt steering column in lowest position. Carefully pry
bezel away from instrument panel to disengage clips. Pull bezel away
far enough to clear trip odometer reset button. Remove bezel.
3) Remove 3 bolts from heater control panel. Pull heater
control panel outward enough to disconnect electrical connectors and