1999 DODGE RAM brake

CAUTION: Disconnect negative battery cable before servicing any air
bag system, steering column or passenger side dash
component. After any repair, turn ignition key to the ON
position from passenger's side of vehicle in case of
accidental air bag inflation
AIR CONDITIONING SERVICING
WARNING: Avoid breathing R-134a refrigerant and PAG lubricant vapors,
exposure may irritate eyes, nose and throat. To remove
R-134a from system use R-134a recycling equipment that meets
SAE J2210 specifications. If accidental system discharge
occurs, ventilate work area before resuming service.
WARNING: R-134a service equipment or vehicle A/C systems SHOULD NOT
be pressure tested or leak tested with compressed air. Some
mixtures of air/R134a have shown to be combustible at
elevated pressures. These mixtures are dangerous and may
cause fire and/or explosions. See AIR CONDITIONING SERVICE
article in GENERAL INFORMATION section.
AIR CONDITIONING MAINTENANCE
WARNING: NEVER add A/C refrigerant to correct a non-cooling problem
unless pressure gauges are connected to the system by a
certified technician. Lack of cooling may be caused by a
restriction, therefore adding refrigerant can cause a
dangerous pressure rise.
ANTI-LOCK BRAKE SYSTEM
CAUTION: The anti-lock brake system contains electronic equipment that
can be susceptible to interference caused by improperly
installed or high output radio transmitting equipment. Since
this interference could cause the possible loss of the
antilock braking capability, such equipment should be
installed by qualified professionals.
On models equipped with anti-lock brake systems, ALWAYS
observe the following cautions:
* DO NOT attempt to bleed hydraulic system without first
referring to the appropriate ANTI-LOCK BRAKE SYSTEM article
in the BRAKES Section.
* DO NOT mix tire sizes. As long as tires remain close to the
original diameter, increasing the width is acceptable.
Rolling diameter must be identical for all 4 tires. Some
manufacturers recommend tires of the same brand, style and
type. Failure to follow this precaution may cause inaccurate
wheel speed readings.
* Use ONLY recommended brake fluids. DO NOT use silicone brake
fluids in an ABS-equipped vehicle.
AUTOMATIC TRANSAXLE FLUID SERVICE
WARNING: Make certain no fluid is spilled when the transaxle fluid
is inspected. Wipe up any spilled fluid completely.
AXLE FLUID
CAUTION: Axle lubricant should be changed whenever the axle has

been submerged in water. Water can enter through the axle
vent hole and contaminate the lubricant.
BATTERY WARNING
WARNING: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure.
WARNING: Batteries produce flammable hydrogen gas. Keep flames and
sparks away from the battery or and explosion may occur.
Never smoke when working in the vicinity of the battery.
WARNING: When checking or servicing the battery, disconnect the
negative cable. Be careful not to cause a short circuit by
allowing metal objects to contact the battery posts and the
vehicle at the same time.
REPLACING BLOWN FUSES
CAUTION: Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical
system. Be sure to use fuse with the correct indicated
amperage rating. The use of an incorrect amperage rating fuse
may result in a dangerous electrical system overload.
BRAKE PAD WEAR INDICATOR
Indicator will cause a squealing or scraping noise, warning
that brake pads need replacement.
BRAKE HOSES
WARNING: Worn brake hoses can burst and cause brake failure. If
any sign of cracking, scuffing, or worn spots are found,
replace the brake hoses immediately.
BRAKE FLUID
WARNING: The use of incorrect fluid in the brake system may cause
damage to components. DO NOT use any fluid other than DOT-3
brake fluid. DO NOT use reclaimed fluid or fluid that has
been stored in old or open containers. It is essential that
foreign particles and other liquids are kept out of the
brake fluid reservoir.
CATALYTIC CONVERTER
CAUTION: Continued operation of vehicle with a severe malfunction
could cause converter to overheat, resulting in possible
damage to converter and vehicle.
COOLANT
CAUTION: To avoid possible damage to vehicle use only ethylene-glycol
based coolants with a mixture ratio from 50-70% anti-freeze.
DO NOT use 100% anti-freeze as it will cause the formation
of cooling system deposits.
DIESEL FUEL ANTI-FUNGAL ADDITIVES

Fig. 20: Underhood Power Distribution Center
Courtesy of Chrysler Corp.
WARNING: Always disconnect battery ground cable before servicing
"high-current fuses. It is recommended that "high-current"
fuses be replaced by a qualified technician.
Power Distribution Center Relay & Fuse Identification
A - Starter Relay
B - Trailer Lights Relay
C - Auto Transmission Relay
D - Anti-Lock Brake System Relay
E - Auto Shutdown Relay
F - Air Conditioning Clutch Relay
G - Horn Relay
H - Fuel System Relay
J - ABS Warning Light Relay
K - Fog Lamp 2 Relay
L - Fog Lamp 1 Relay
1 - 30 Amp (Pink)
Engine Control
2 - 40 Amp (Green)
Ignition Run/Accessory
3 - 40 Amp (Green)
Ignition Run
4 - 50 Amp (Red)
Instrument Panel, Horn, Parking Lights
5 - 20 Amp (Blue)
Fuel Pump
6 - 30 Amp (Pink)
Trailer Lights
7 - 40 Amp (Green)
Stop/Headlight
8 - 40 Amp (Green)
ABS Pump
9 - 20 Amp (Yellow)
Hazard Lights
10 - 20 Amp (Yellow)
Horn/AC
11 - 15 Amp (Blue)

Removal (A/T Models)
Raise and support vehicle. Disconnect electrical connector
from park/neutral switch. Park/neutral switch is located on side of
transmission case, near shift linkage. Unscrew park/neutral switch
from transmission case. Remove seal ring from park/neutral switch.
Installation
1) Apply parking brake. Place shift lever in Park and
Neutral. Ensure park/neutral switch operating levers in transmission
are centered in the park/neutral switch opening on transmission case.
2) Using NEW seal ring, install park/neutral switch. Tighten
park/neutral switch to specification. See TORQUE SPECIFICATIONS.
Install electrical connector. Add ATF as necessary.
ACCELERATOR PEDAL POSITION SENSOR (APPS)
NOTE: APPS is replaced as assembly, including lever, brackets, and
sensor.
Removal
1) Disconnect negative battery cables. Remove cable cover.
Using finger pressure only, disconnect end of speed control servo
cable from throttle lever pin by pulling forward on connector while
holding lever rearward. Using 2 small screwdrivers, pry throttle cable
connector socket from throttle lever ball.
2) Disconnect transmission kickdown cable (if equipped).
Compress pinch tabs on cruise control and throttle cables. Pull cables
rearward to remove from cable mounting brackets. See Fig. 4.
Disconnect electrical connector and retaining bolts. Remove APPS
sensor.
Installation
To install, reverse removal procedure. To calibrate ECM, turn
ignition on. Without starting engine, slowly press throttle pedal to
floor and then slowly release.
Fig. 4: Locating Throttle Position (TP) Sensor
Courtesy of Chrysler Corp.
RELAYS & SOLENOIDS

FUEL LINE BLEEDING
NOTE: Fuel line bleeding is necessary if fuel injection pump is
replaced, fuel filter/water separator is not filled with
diesel fuel before installing or vehicle ran out off fuel.
Bleed high-pressure fuel lines if connections are loosened or
replaced. If engine has not been operated for an extended
time, bleed fuel lines before next initial engine start-up.
WARNING: DO NOT bleed fuel lines on a hot engine, as high exhaust
temperatures may cause a fire. Carefully bleed fuel lines, as
fuel is under extremely high pressure and could penetrate
skin. Use safety goggles and protective clothing when
bleeding fuel lines.
1) Loosen banjo bolt holding low-pressure fuel supply line to
side of fuel injection pump. Wrap a towel around banjo fitting to
catch fuel. Crank engine quickly and release key before engine starts.
This will operate fuel transfer pump for about 25 seconds.
2) If fuel is not present at fuel supply line after 25
seconds, turn ignition off. Repeat engine crank procedure until fuel
is present at fuel supply line. Tighten banjo bolt at fuel supply line
to specification. See TORQUE SPECIFICATIONS.
CAUTION: Ensure parking brake is applied and transmission is in
Neutral before bleeding fuel injection pump or high-pressure
fuel lines. DO NOT operate starter for more than 30 seconds
when bleeding fuel injection pump or high-pressure fuel
lines. Allow 2-minute intervals between starter operations.
3) To bleed air from fuel injection pump, ensure parking
brake is applied and transmission is in Neutral, as engine may start
when operating starter to bleed air from fuel injection pump. Operate
starter for 30 seconds to bleed any trapped air in fuel injection
pump.
4) To bleed high-pressure fuel lines, ensure parking brake is
applied and transmission is in Neutral, as engine may start when
operating starter to bleed high-pressure fuel lines. Loosen high-
pressure fuel line nut at fuel injector.
5) Operate starter until steady fuel flow exists at high-
pressure fuel line. Tighten high-pressure fuel line nut to
specification. See TORQUE SPECIFICATIONS. Start engine. Repeat
procedure on each high-pressure fuel line until engine operates
smoothly.
FUEL FILTER/WATER SEPARATOR & WATER-IN-FUEL SENSOR
NOTE: Vehicle also contains an in-tank fuel filter located on
bottom of fuel tank module. For servicing procedure, see FUEL
TANK MODULE & IN-TANK FUEL FILTER under FUEL SYSTEM.
NOTE: When fuel filter/water separator is being replaced,
manufacturer recommends cleaning the pre-filter. See FUEL
HEATER under FUEL SYSTEM for servicing of pre-filter.
Removal
1) Ensure engine is off. Place drain pan below drain tube at
fuel filter/water separator. See Fig. 3. Rotate handle on drain valve
forward, toward front of vehicle to DRAIN position. Drain valve is
located near top of fuel filter/water separator. See Fig. 3. Once fuel
is drained from fuel filter/water separator, rotate handle on drain
valve back to CLOSE position.


N - R EM OVE/IN STA LL/O VER HAU L - R W D - G ASO LIN E

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Removal, Overhaul & Installation - Gasoline
Dakota, Durango, Ram Pickup, Ram Van, Ram Wagon
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.
INTRODUCTION
Removal, overhaul and installation procedures are covered in
this article. If component removal and installation is basically an
unbolt and bolt-on procedure, only a torque specification may be
provided.
COMPUTERIZED ENGINE CONTROLS
POWERTRAIN CONTROL MODULE (PCM)
NOTE: If replacing Powertrain Control Module (PCM), the correct
vehicle mileage and Vehicle Identification Number (VIN) must
be programmed into the PCM to prevent Diagnostic Trouble
Codes (DTCs) from being set in the Anti-Lock Brake System
(ABS) module and Supplemental Restraint System (SRS) module\
.
To program PCM and clear DTCs from ABS and SRS modules, see
PCM PROGRAMMING. If replacing Powertrain Control Module (PCM)\
on models equipped with a Smart Key Immobilizer Module
(SKIM), the secret key data must also be updated to enable
engine starting. To update secret key data, see PCM
PROGRAMMING.
Removal & Installation
1) PCM is located in the engine compartment. See Figs. 1-3.
Disconnect negative battery cable. Remove cover for access to
electrical connectors at PCM. Disconnect electrical connectors from
PCM. Remove PCM retaining bolts and PCM.
2) To install, reverse removal procedure. Tighten PCM
retaining bolts to specification. See TORQUE SPECIFICATIONS.
Fig. 1: Locating PCM (Dakota & Durango)
Courtesy of Chrysler Corp.

Procedure For Programming PCM & Clearing DTCs From ABS & SRS
Modules
Connect scan tool to Data Link Connector (DLC). DLC is
located under left side of instrument panel. Using scan tool, enter
correct VIN and mileage into PCM. Using scan tool manufacturer's
instructions, clear DTCs from ABS and SRS modules.
Procedure For Updating Secret Key Data
1) Connect scan tool to Data Link Connector (DLC). DLC is
located under left side of instrument panel.
2) Go to ENGINE and then MISC menus on scan tool. Place the
SKIM in SECURED ACCESS MODE by using the appropriate Personal
Identification Number (PIN) for this vehicle. PIN may be obtained from\
the owner, vehicle's invoice, or from the manufacturer. Select UPDATE
THE SECRET KEY DATA. The data will be transferred from Smart Key
Immobilizer Module (SKIM) to the PCM, allowing the vehicle to start.
NOTE: On Ram Van and Ram Wagon, if 3 attempts are made to enter the
SECURED ACCESS MODE using the incorrect Personal
Identification Number (PIN), the SECURED ACCESS MODE will be
locked out for one hour. To exit this locked out mode, leave
ignition switch in the ON position for one hour with all
accessories turned off. It may be necessary to monitor
battery state and connect a battery charger if necessary.
ENGINE SENSORS & SWITCHES
BATTERY TEMPERATURE SENSOR
Removal & Installation
Battery temperature sensor is snapped into center of battery
tray, directly below the battery. Remove battery. Disconnect
electrical connector for battery temperature sensor. Pry battery
temperature sensor straight upward from battery tray. To install,
reverse removal procedure.
BRAKE SWITCH
NOTE: Brake switch may also be referred to as brakelight switch or
stoplight switch.
Removal (Dakota, Durango & Ram Pickup)
1) Brake switch is located near top of brake pedal. Remove
lower instrument panel cover for access to brake switch if necessary.
Disconnect electrical connector from brake switch. Depress and hold
brake pedal downward.
2) Rotate brake switch counterclockwise approximately 30
degrees so alignment tab on brake switch aligns with opening on
mounting bracket. Pull brake switch rearward from mounting bracket.
NOTE: Before installing brake switch, plunger on brake switch must
be pulled outward to fully extended position and then pushed
inward 4 detent positions to ensure proper brake switch
adjustment.
Installation
1) Pull plunger on brake switch outward to the fully extended
position. Push plunger on brake switch inward 4 detent positions. The
brake switch will click at each detent position when pushing plunger
inward.
2) Install electrical connector on brake switch. Depress
brake pedal as far as possible. Install brake switch in mounting

bracket. Ensure alignment tab on brake switch aligns with opening on
mounting bracket.
CAUTION: When adjusting brake switch, DO NOT pull brake pedal back
toward brake switch with excessive pressure, or brake switch
may be damaged.
3) When brake switch is fully installed in mounting bracket,
rotate brake switch clockwise approximately 30 degrees. To ensure
proper brake switch adjustment, gently pull brake pedal back toward
brake switch as far as possible. DO NOT apply excessive pressure on
brake pedal and brake switch.
Removal (Ram Van & Ram Wagon)
1) Brake switch is located near top of brake pedal. Remove
lower steering column cover. Remove data link connector, hood release
lever and parking brake lever from lower instrument panel cover.
2) Remove lower instrument panel cover for access to brake
switch. Depress and hold brake pedal downward. Rotate brake switch
counterclockwise approximately 1/16 turn to so locking collar on brake
switch aligns with opening on mounting bracket. Pull brake switch
rearward from mounting bracket. Disconnect electrical connector from
brake switch.
NOTE: Before installing brake switch, plunger on brake switch must
be pulled outward to fully extended position and then pushed
inward 4 detent positions to ensure proper brake switch
adjustment.
Installation
1) Pull plunger on brake switch outward to the fully extended
position. Push plunger on brake switch inward 4 detent positions. The
brake switch will click at each detent position when pushing plunger
inward.
2) Install electrical connector on brake switch. Depress
brake pedal as far as possible. Install brake switch in mounting
bracket. Ensure locking collar on brake switch aligns with opening on
mounting bracket.
CAUTION: When adjusting brake switch, DO NOT pull brake pedal back
toward brake switch with excessive pressure, or brake switch
may be damaged.
3) When brake switch is fully installed in mounting bracket,
rotate brake switch clockwise approximately 1/16 turn. To ensure
proper brake switch adjustment, gently pull brake pedal back toward
brake switch as far as possible. DO NOT apply excessive pressure on
brake pedal and brake switch.
CAMSHAFT POSITION SENSOR
Removal & Installation
See CAMSHAFT POSITION SENSOR under IGNITION SYSTEM.
CRANKSHAFT POSITION SENSOR
Removal & Installation
See CRANKSHAFT POSITION SENSOR under IGNITION SYSTEM.
DOWNSTREAM OXYGEN SENSOR
NOTE: Downstream oxygen sensor may also be referred to as post
-catalyst oxygen sensor.