1999 DODGE RAM fuel


D - A D JU STM EN TS - D IE SEL

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - On-Vehicle Adjustments - Trucks - Diesel
Ram Pickup
ENGINE MECHANICAL
Before performing any on-vehicle adjustments to fuel system,
ensure engine mechanical condition is okay.
VALVE CLEARANCE
NOTE: Valve clearance must be adjusted with engine temperature less
than 140F (60C).
1) Disconnect negative battery cables. Remove valve cover.
Remove fuel pump gear access cover, located at front of engine. Using
Engine Barring Tool (7471B), rotate engine to align pump gear mark
with TDC mark on gear housing cover. See Fig. 1.
Fig. 1: Rotating Engine
Courtesy of Chrysler Corp.
2) With cylinder No. 1 at TDC, check valve clearance on
proper valves. Perform STEP 1. See Fig. 2. See VALVE CLEARANCE

ADJUSTING SEQUENCE table. Using feeler gauge, check valve clearance
between rocker arm socket and crosshead. Ensure valve clearance is
within specification. See VALVE CLEARANCE SPECIFICATIONS table. If
valve clearance is within specification, go to next step. If any valve
clearance is not within specification, loosen rocker lever adjusting
screw lock nut, and adjust valve clearance by rotating rocker lever
adjusting screw. Tighten rocker lever adjusting screw lock nut to
specification. See TORQUE SPECIFICATIONS. When all valve clearances
are within specification, go to next step.
Fig. 2: Identifying Fuel Pump Gear Timing Mark Orientation
Courtesy of Chrysler Corp.
VALVE CLEARANCE ADJUSTING SEQUENCE









\









\









\









\









\









\









\








Procedure Cylinders No.
Step 1 (1)
Intake Valve ............................................ 1, 2 & 4
Exhaust Valve ........................................... 1, 3 & 5
Step 2 ( 2)
Intake Valve ............................................ 3, 5 & 6
Exhaust Valve ........................................... 2, 4 & 6
( 1) - Perform STEP 1. See Fig. 2.
( 2) - Rotate engine clockwise (viewed from front of engine) one full
revolution from TDC on cylinder No. 1 (STEP 1) and align
reference marks. Perform STEP 2. See Fig. 2.









\









\









\









\









\









\









\








VALVE CLEARANCE SPECIFICATIONS ( 1)








\









\









\









\









\









\









\








Application In. (mm)\
Intake Valve ............................. ( 2) .006-.015 (.152-.381)
Exhaust Valve ............................ ( 3) .015-.030 (.381-.762)
( 1) - Adjust valve clearance with engine temperature less than
140
F (60C).
( 2) - Set to .010" (.254 mm) if adjustment is necessary.
( 3) - Set to .020" (.508 mm) if adjustment is necessary.









\









\









\









\









\









\









\








3) Rotate engine clockwise (viewed from front of engine) one\
full revolution from TDC on cylinder No. 1 and align reference marks.
Check valve clearance on proper valves. Perform STEP 2. See Fig. 2.
See VALVE CLEARANCE ADJUSTING SEQUENCE table. Ensure valve clearance
is within specification. See VALVE CLEARANCE SPECIFICATIONS table. If
valve clearance is within specification, go to next step. If valve
clearance is not within specification, loosen rocker lever adjusting
screw lock nut, and adjust valve clearance by rotating rocker lever
adjusting screw. Tighten rocker lever adjusting screw lock nut to
specification. See TORQUE SPECIFICATIONS. Go to next step.
4) Install valve cover, fuel pump access cover and battery
cables.
FUEL INJECTION PUMP TIMING
CHECKING FUEL INJECTION PUMP TIMING
NOTE: With Bosch VP 44 pump, no mechanical adjustments are
necessary. All timing and fuel adjustments are performed by
Engine Control Module (ECM). If a FTC indicating engine sync
error or static timing error has been set, perform following
adjustment. If FTC sets after installing a new pump, pump
keyway has probably been installed backward.
CAUTION: DO NOT allow nut and washer to fall inside front cover.
1) Remove fuel pump access cover, shaft nut and washer.
Ensure keyway aligning pump shaft to pump gear has not slipped. If
keyway has slipped, repair as necessary.
2) Remove timing gear cover. See REMOVAL, OVERHAUL &
INSTALLATION - TRUCKS - DIESEL article. Using a T-type puller, remove
injection pump gear from shaft. Ensure key has been installed in
keyway with arrow pointing to rear of pump. Pump timing is calibrated
to pump keyway. Ensure 3-digit number on key matches number on pump

data plate. See Fig. 3. There are 21 different calibrations available.
Repair as necessary.
Fig. 3: Identifying Pump Keyway & Pump Data Plate
Courtesy of Chrysler Corp.
3) Reinstall pump timing gear. Ensure timing marks on
crankshaft gear, camshaft gear and fuel pump gear are aligned. See

step.
7) Turn engine off. Drain transmission fluid and remove oil
pan. Inspect oil pan for burnt oil and debris. Repair transmission as
necessary. See appropriate AUTOMATIC TRANSMISSION OVERHAUL article. If
transmission is okay, no problem is found at this time, see INACTIVE
DTC CONDITION under SELF-DIAGNOSTIC SYSTEM. Testing is complete.
8) Leave gauges connected. Replace 3-4 shift solenoid.
Replace transmission pan and fill with fluid. Start engine and allow
engine and transmission to reach normal operating temperature. Using
scan tool, select GOV and 3-4 SHIFT VALVE SYSTEM TEST. Select 4th gear
while monitoring pressure gauges. Governor pressure should rise to
greater than 20 psi (1.4 kg/cm
) and O/D pressure should rise to
greater than 40 psi (2.8 kg/cm). If pressures are as specified, no
problem is found at this time. Testing is complete. If pressures are
not as specified, see appropriate AUTOMATIC TRANSMISSION OVERHAUL
article, paying attention to seals and clutches related to O/D clutch.
DTC P1740: TCC OR O/D SOLENOID PERFORMANCE (BR BODY - DIESEL)
Circuit Description
Torque Converter Clutch (TCC) and overdrive clutch are tested\
when Powertrain Control Module (PCM) requests TCC engagement in 3rd
gear and overdrive. Code will set if expected RPM drop is not achieved
while attempting to engage TCC and/or overdrive. Code indicates
malfunctioning torque converter or overdrive clutch.
Possible Causes
* Fluid level or quality problem.
* Transmission wiring and connector defective.
* Transmission mechanically defective.
* Low fuel level.
* Trans temperature below 32
.
* Transfer case is in low range.
* Engine RPM trouble codes set.
* Misfire trouble code set (DTCs P0300-P0306).
* Output shaft speed trouble code set.
* PTO is engaged.
* TPS codes set (DTCs P0121-P0123).
* Torque converter defective.
Diagnostic Procedures
1) Using scan tool, read DTCs. If DTC SPECIFIC GOOD TRIPS
counter is not displayed or displayed count is not "0", go to step
16). If DTC SPECIFIC GOOD TRIPS counter is displayed and displayed
count is "0", go to next step.
2) If any DTCs listed are present, perform appropriate
test(s). See TCC OR O/D SOLENOID TESTS table. If no DTCs are present,
go to next step.
TCC OR O/D SOLENOID TESTS









\









\









\









\









\









\









\







DTC Message Test
CAMSHAFT POSITION SENSOR SIGNAL .......................... ( 1) P0341
P/N SWITCH STUCK IN PARK OR IN GEAR .......................... P1899
Any Throttle Position Sensor (TPS) DTC ......................... ( 1)
Any Misfire DTC ................................................ ( 1)
Any Engine RPM DTC ............................................. ( 1)
Any Output Shaft Speed Sensor DTC .............................. ( 1)
TRANS 12-VOLT SUPPLY RELAY CNTRL CIRCUIT ..................... P1765
TORQUE CONVERTOR CLUTCH SOLENOID/TRANS RELAY CIRCUITS ........ P0743
TRANS 3-4 SHIFT SOLENOID/TRANS RELAY CIRCUITS ................ P0753

(1) - See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.








\









\









\









\









\









\









\







3) Ensure fuel tank is at least 1/4 full. If fuel level is
too low, correct fuel level and retest. If fuel level is okay, go to
next step.
4) Ensure transfer case is not in low range. Shift transfer
case out of low range. If transfer case is not in low range, go to
next step.
5) Ensure PTO is not engaged. Disengage PTO. If PTO is not
engaged, go to next step.
6) Ensure transmission fluid temperature is above 32
F (0C).
Warm transmission to normal operating temperature. If transmission
fluid temperature is above 32
F (0C), go to next step.
7) Turn ignition on. Using scan tool, build a custom display
with engine RPM, output shaft SPD, TCC solenoid, O/D solenoid and
throttle position. Set overdrive to off position. Road test vehicle
and reach a steady speed of 55 MPH with a minimum throttle opening
voltage of 1.15 volts for 20 seconds. Note shift patterns while
vehicle is attaining speed. If engine RPM is within 60 RPM of output
shaft speed RPM, go to next step. If engine RPM is not within 60 RPM
of output shaft speed RPM, go to step 15).
8) If output shaft speed RPM is greater than engine RPM, go
to next step. If output shaft speed RPM is equal to or less than
engine RPM, go to step 15).
9) Road test vehicle and reach a steady speed of 55 MPH and
engage overdrive. If engine RPM is 69 percent of output shaft speed,
go to step 15). If engine RPM is not 69 percent of output shaft speed,
go to next step.
10) Connect a 0-300 psi (0-21 kg/cm
) pressure gauge to
transmission Overdrive (O/D) clutch pressure test port. Connect a
second 0-300 psi (0-21 kg/cm
) pressure gauge to transmission governor
pressure test port. See appropriate AUTOMATIC TRANSMISSION OVERHAUL
article. Ensure engine and transmission are at normal operating
temperature. With an assistant, test drive vehicle. Using scan tool,
select GOV and 3-4 SHIFT VALVE SYSTEM TEST. Select 4th gear while
monitoring pressure gauge. Governor pressure should rise to greater
than 20 psi (1.4 kg/cm
) and O/D pressure should rise to greater than
40 psi (2.8 kg/cm). If pressures are as specified, go to next step.
If pressures are not as specified, go to step 13).
11) Check transmission fluid for proper level and for any
debris. Fill or repair transmission as necessary. If fluid level and
condition are okay, go to next step.
12) Drain transmission fluid and remove oil pan. If
transmission fluid is burnt or has excessive debris, repair as
necessary. If transmission fluid is okay, go to step 23).
13) Check transmission fluid for proper level and for any
debris. Fill or repair transmission as necessary. If fluid level and
condition are okay, go to next step.
14) Leave gauges connected. Replace 3-4 shift solenoid. Start
engine and allow engine and transmission to reach normal operating
temperature. Using scan tool, select GOV and 3-4 SHIFT VALVE SYSTEM
TEST. Select 4th gear while monitoring pressure gauges. Governor
pressure should rise to greater than 20 psi (1.4 kg/cm
) and O/D
pressure should rise to greater than 40 psi (2.8 kg/cm). If pressures
are as specified, testing is complete. If pressures are not as
specified, see appropriate AUTOMATIC TRANSMISSION OVERHAUL article,
paying attention to seals and clutches related to O/D clutch.
15) Check transmission fluid for proper level and for any
debris. Fill or repair transmission as necessary. If fluid level and
condition are okay, go to next step.
16) Start engine. Using scan tool, perform TCC SYSTEM TEST.

article in ENGINE PERFORMANCE for diagnosis by symptom. If initial
symptom no longer exists, test is complete. Go to step 6).
2) If PCM has not been replaced, and TEST VER-2A (DIESEL) is\
being performed after a DTC test, inspect vehicle to ensure all engine
components are connected. Reassemble and reconnect components as
necessary. Using scan tool, erase DTCs, reset all memory values and go
to step 4).
3) If PCM has not been replaced, and TEST VER-2A (DIESEL) is\
being performed after an A/C relay control circuit DTC test, ensure
A/C is on and go to next step.
4) Road test vehicle for at least 5 minutes. Road test
vehicle at a speed of at least 40 MPH at some point during road test.
Stop vehicle. Turn engine off for at least 10 seconds. Start engine
and continue road test. Ensure transmission shifts through all gears.
After road test, turn engine off and go to next step.
5) Using scan tool, read DTCs. If any DTC returns, perform
appropriate test(s). If no DTCs return, test is complete. Go to next
step.
6) Turn ignition on, with engine off. Using scan tool, erase
DTCs. Turn ignition off. Disconnect scan tool. Test is complete.
TEST VER-5A (EXCEPT DIESEL)
NOTE: If Powertrain Control Module (PCM) is replaced, correct
vehicle mileage and Vehicle Identification Number (VIN) must
be programmed into PCM to prevent Diagnostic Trouble Codes
(DTCs) from being set in Anti-Lock Brake System (ABS) modul\
e
and Supplemental Restraint System (SRS) module. To program
PCM and clear DTCs from ABS and SRS modules, proceed to
appropriate procedure listed below. On models equipped with a
Smart Key Immobilizer Module (SKIM), if replacing Powertrain
Control Module (PCM), secret key data must also be updated to\
enable engine starting. To update secret key data, proceed to
appropriate procedure listed below.
Procedure For Programming PCM & Clearing DTCs From ABS & SRS
Modules
Connect scan tool to Data Link Connector (DLC). Using scan
tool, enter correct VIN and mileage into PCM. Using scan tool
manufacturer's instructions, clear DTCs from ABS and SRS modules. Go
to step 1)).
Procedure For Updating Secret Key Data
Connect scan tool to Data Link Connector (DLC). Go to ENGINE
and then MISC menus on scan tool. Place SKIM in SECURED ACCESS MODE by
using appropriate Personal Identification Number (PIN) for this
vehicle. PIN may be obtained from owner, vehicle's invoice, or from
manufacturer. Select UPDATE THE SECRET KEY DATA. Data will be
transferred from Smart Key Immobilizer Module (SKIM) to PCM. Go to
step 1)).
1) Inspect vehicle to ensure all engine components are
connected. Reassemble and reconnect components as necessary. If any
DTCs have not been diagnosed, return to appropriate test(s). If all
DTCs have been diagnosed and repaired, go to next step.
2) Connect scan tool to Data Link Connector (DLC) if not
previously done. Ensure fuel tank is at least 1/4 full. Ensure A/C is
off. Go to next step.
3) Proper way to ensure DTC is repaired is to allow
Powertrain Control Module (PCM) to run monitor. Monitor operation may
be observed on scan tool. All specified enabling conditions for
specified DTC must be met before PCM will operate monitor. Go to next
step.

4) Using scan tool, monitor pretest enabling conditions until
all conditions have been met. Once all enabling conditions are met,
observe appropriate monitor for DTC on scan tool. If repaired DTC has
reset or is seen on monitor while on road test, repair is not
complete. Check for related Technical Service Bulletins (TSBs) and
return to appropriate test. If no DTCs return, test is complete. Go to
step 6).
5) If another DTC exists, return to appropriate test(s). If
no DTCs return, test is complete. Go to next step.
6) Turn ignition on, with engine off. Using scan tool, erase
DTCs. Turn ignition off. Disconnect scan tool. Test is complete.
TEST VER-5A (DIESEL)
NOTE: If Accelerator Pedal Position Sensor (APPS), battery, Engine
Control Module (ECM) or Powertrain Control Module (PCM) has\
been disconnected or replaced, APPS must be reprogrammed and
correct vehicle mileage and Vehicle Identification Number
(VIN) must be programmed into PCM to prevent Diagnostic
Trouble Codes (DTCs) from being set in Anti-Lock Brake System\
(ABS) module and Supplemental Restraint System (SRS) module\
.
To program PCM and clear DTCs from ABS and SRS modules,
proceed to appropriate procedure listed below. On models
equipped with a Smart Key Immobilizer Module (SKIM), if
replacing Powertrain Control Module (PCM), secret key data
must also be updated to enable engine starting. To update
secret key data, proceed to appropriate procedure listed
below.
CAUTION: DO NOT attempt to adjust screws or disassemble APPS. Settings
are preset at factory and are not intended to by changed.
Procedure For Programming APPS
Reassemble all components. Turn ignition switch to ON or RUN
position without starting engine. Slowly press accelerator pedal to
floor once and slowly release. This procedure programs APPS
calibration in ECM. Go to step 1)).
Procedure For Programming PCM & Clearing DTCs From ABS & SRS
Modules
Connect scan tool to Data Link Connector (DLC). Using scan
tool, enter correct VIN and mileage into PCM. Using scan tool
manufacturer's instructions, clear DTCs from ABS and SRS modules. Go
to step 1)).
Procedure For Updating Secret Key Data
Connect scan tool to Data Link Connector (DLC). Go to ENGINE
and then MISC menus on scan tool. Place SKIM in SECURED ACCESS MODE by
using appropriate Personal Identification Number (PIN) for this
vehicle. PIN may be obtained from owner, vehicle's invoice, or from
manufacturer. Select UPDATE THE SECRET KEY DATA. Data will be
transferred from Smart Key Immobilizer Module (SKIM) to PCM. Go to
step 1)).
1) If PCM has not been replaced, inspect vehicle to ensure
all engine components are connected. Reassemble and reconnect
components as necessary. If any DTCs have not been diagnosed, return
to appropriate test(s). If all DTCs have been diagnosed and repaired,
go to next step.
2) Ensure fuel tank is at least 1/4 full. Ensure A/C is off.
Proper way to ensure DTC is repaired is to connect scan tool to Data
Link Connector (DLC) and allow Powertrain Control Module (PCM) to ru\
n
a DTC SPECIFIC GOOD TRIP COUNTER for 2 minutes. If DTC SPECIFIC GOOD