1999 DODGE RAM Service Repair Manual

Fig. 9: Electrical, Radio & Tape/CD Player

Fig. 10: Manual Transmission & Clutch

Fig. 11: Squeak, Rattle, & Noise Conditions
Fig. 12: Water Leak & Wind Noise


I - S YSTE M /C O M PO NEN T T E STS

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - System & Component Testing - Trucks - Diesel
Ram Pickup
INTRODUCTION
Before testing separate components or systems, perform
procedures in BASIC DIAGNOSTIC PROCEDURES - TRUCKS - DIESEL article.
Since many computer-controlled and monitored components set a
diagnostic trouble code if they malfunction, also perform procedures
in SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS article.
NOTE: Testing individual components does not isolate short or open
circuits. Perform all voltage tests with a Digital Volt
-Ohmmeter (DVOM) with a minimum 10-megohm input impedance,
unless stated otherwise in test procedure. Use ohmmeter to
isolate shorted or open wiring harness.
AIR INDUCTION SYSTEMS
INTAKE MANIFOLD AIR HEATER SYSTEM
For testing information on intake manifold air heater system,
perform procedures in SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS
article.
INTERCOOLER
Cleaning and inspection procedures for intercooler is the
only information available from manufacturer. See INTERCOOLER under
AIR INDUCTION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - TRUCKS -
DIESEL article.
TURBOCHARGER
NOTE: Manufacturer does not recommend turbocharger disassembly.
Turbocharger overhaul should be performed only by an
authorized repair facility.
Turbocharger Boost Pressure
Turbocharger boost pressure testing information is not
available at time of publication.
TURBOCHARGER WASTEGATE
See CONTROL ROD ADJUSTMENT under TURBOCHARGER WASTEGATE in
ON-VEHICLE ADJUSTMENTS - TRUCKS - DIESEL article.
COMPUTERIZED ENGINE CONTROLS
POWERTRAIN CONTROL MODULE (PCM)
The PCM is located on firewall at passenger's side rear
corner of engine compartment. See Fig. 1. The PCM power and ground
circuits may be checked by performing specified test. See DTC P0601 in
SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS article.

Fig. 1: Locating Powertrain Control Module (PCM)
Courtesy of Chrysler Corp.
ENGINE SENSORS & SWITCHES
SENSORS
Battery Temperature Sensor
1) Battery temperature sensor is snapped into battery tray,
below driver's side battery. Disconnect wiring harness at battery
temperature sensor.
2) Using ohmmeter, check resistance between electrical
terminals on battery temperature sensor. Resistance should be 9000-11,
000 ohms at 75-80
F (25-27C). Replace battery temperature sensor if
resistance is not within specification.
3) If problem exists in battery temperature sensor or wiring
circuit, a Diagnostic Trouble Code (DTC) will be stored in Powertrain
Control Module (PCM). See SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS
article.
Crankshaft Position Sensor
If problem exists in crankshaft position sensor, a Diagnostic
Trouble Code (DTC) will be stored in Powertrain Control Module (PCM)\
.
See appropriate crankshaft position sensor test in SELF-DIAGNOSTICS -
JEEP, TRUCKS & RWD VANS article.
Fuel Heater Temperature Sensor
See FUEL DELIVERY under FUEL SYSTEM.
Intake Manifold Air Temperature Sensor
Intake manifold air temperature sensor is located on top of
intake manifold, behind intake manifold air heater. For testing, see
DTC P0113: INTAKE AIR TEMPERATURE SENSOR VOLTAGE HIGH test in SELF-
DIAGNOSTICS - JEEP, TRUCKS & RWD VANS article.
Transmission Governor Pressure Sensor (A/T Models)

See TRANSMISSION under MISCELLANEOUS CONTROLS.
Transmission Speed Sensor (A/T Models)
See TRANSMISSION under MISCELLANEOUS CONTROLS.
Transmission Temperature Sensor (A/T Models)
See TRANSMISSION under MISCELLANEOUS CONTROLS.
Water-In-Fuel (WIF) Sensor
Water-in-fuel sensor is located in bottom of fuel
filter/water separator. Testing information not available from
manufacturer.
SWITCHES
Brake Switch
1) Remove lower panel for access to brake switch. Brake
switch is located on bracket, near top of brake pedal. Disconnect
electrical connector from brake switch. Pull plunger on brake switch
fully outward. See Fig. 2.
2) Using ohmmeter, check for continuity between terminals No.
5 and 6 on brake switch. See Fig. 2. Continuity should exist. If
continuity exists, go to next step. If continuity does not exist,
replace brake switch.
3) Push plunger on brake switch fully inward. Using ohmmeter,
check for continuity between terminals No. 1 and 2, and 3 and 4 on
brake switch. See Fig. 2. Continuity should exist. If continuity does
not exist, replace brake switch.
Fig. 2: Identifying Brake Switch Terminals
Courtesy of Chrysler Corp.
Park/Neutral Switch (A/T Models)
See TRANSMISSION under MISCELLANEOUS CONTROLS.

Transmission Overdrive Switch (A/T Models)
See TRANSMISSION under MISCELLANEOUS CONTROLS.
RELAYS & SOLENOIDS
RELAYS
A/C Clutch Relay
A/C clutch relay may also be referred to as A/C compressor
clutch relay. A/C clutch relay is located in power distribution center
at driver's side front corner of engine compartment, near battery. If
problem exists in A/C clutch relay or wiring circuit, a Diagnostic
Trouble Code (DTC) will be stored in Powertrain Control Module (PCM)\
.
See DTC P0645 in SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS article.
Auto Shutdown (ASD) Relay
ASD relay is located in power distribution center at driver's
side front corner of engine compartment, near battery. If problem
exists in ASD relay or wiring circuit, a Diagnostic Trouble Code (DTC)\
will be stored in Powertrain Control Module (PCM). See SELF-
DIAGNOSTICS - JEEP, TRUCKS & RWD VANS article.
Fuel Heater Relay
1) Fuel heater relay is located in Power Distribution Center
(PDC) next to left battery. Refer to PDC lid for relay location.
Remove relay and note terminal identification on relay. See Fig. 3.
2) Using ohmmeter, check resistance between terminals No. 85
and 86 on relay. Resistance should be 70-80 ohms. If resistance is
within specification, go to next step. If resistance is not within
specification, replace relay.
3) Using ohmmeter, ensure continuity exists between terminals
No. 30 and 87A on relay. If continuity exists, go to next step. If no
continuity exists, replace relay.
4) Using ohmmeter, ensure no continuity exists between
terminals No. 30 and 87 on relay. If no continuity exists, go to next
step. If continuity exists, replace relay.
5) Using jumper wires, connect terminal No. 85 to negative
side of 12-volt power source and terminal No. 86 to positive side of
12-volt power source. Using ohmmeter, ensure no continuity now exists
between terminals No. 30 and 87A on relay. If no continuity exists, go
to next step. If continuity exists, replace relay.
CAUTION: DO NOT allow ohmmeter leads to contact terminals No. 85 and
86 on relay when checking resistance.
6) Using ohmmeter, ensure continuity now exists between
terminals No. 30 and 87 on relay. If continuity exists, disconnect
jumper wires from relay. If no continuity exists, replace relay.
NOTE: For additional information on checking wiring circuit for
fuel heater relay, see TEST NTC-1: NO TROUBLE CODE TEST MENU
and TEST NS-SEL: NO START TEST SELECTION in SELF-DIAGNOSTICS
- JEEP, TRUCKS & RWD VANS article.

Fig. 3: Fuel Heater Relay Terminals
Courtesy of Chrysler Corp.
Intake Manifold Air Heater Relays
1) Intake manifold air heater relays may also be referred to
as intake air heater relays. Intake manifold air heater relays are
mounted on inner wheelwell, below driver's side battery. See Fig. 4.
2) Disconnect negative battery cables. Note location of
wiring on intake manifold air heater relays for reassembly reference.
Disconnect all electrical connectors and cables from intake manifold
air heater relays.
3) Connect ohmmeter between large terminals on intake
manifold air heater relay to check for continuity. Using jumper wires,
momentarily apply battery voltage to relay trigger wire terminals
(small wire terminals) at base of intake manifold air heater relay.
See Fig. 4 . Polarity is not important.
4) Intake manifold air heater relay should click and ohmmeter
should indicate continuity between large terminals when battery
voltage is applied to relay trigger wire terminals. If intake manifold
air heater relay operation is not as specified, replace intake
manifold air heater relay with bracket. Test remaining intake manifold
air heater relay. Remove ohmmeter. Reconnect all electrical connectors
and negative battery cables.
NOTE: For additional information on checking wiring circuit for
intake manifold air heater relay, see DTC P0380: INTAKE AIR
HEATER RELAY NO. 1 CONTROL CIRCUIT and DTC P0382: INTAKE AIR
HEATER RELAY NO. 2 CONTROL CIRCUIT tests in SELF-DIAGNOSTICS
- JEEP, TRUCKS & RWD VANS article.