1999 DODGE RAM seats

and wiring for excessive resistance.
(3) - Some integral bearing assemblies with sensors may require
replacement.









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DEFOGGERS
See
HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND SEATS) .
DEFROSTERS
See
HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND SEATS) .
DELAYS
DELAY 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
of hardware.
Binding, affecting
performance ............ A .. Require repair or replacement.
Binding, not affecting
performance ............ 2 .. Suggest repair or replacement.
Broken .................. A .. Require repair or replacement.
Burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Burned, not affecting
performance ............ 2 ........... ( 1) Suggest repair or
replacement.
Cracked, affecting
performance ............ A .. Require repair or replacement.
Cracked, not affecting
performance ............ 1 .. Suggest repair or replacement.
Inoperative ............. A ........... ( 2) Require repair or
replacement.
Melted, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Melted, not affecting
performance ............ 2 ........... ( 1) Suggest repair or
replacement.
Missing ................. C ............ 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

Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of OEM
specification.









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ELECTRIC HEATERS
See
HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND SEATS) .
EQUALIZERS
See
RECEIVERS, AMPLIFIERS, EQUALIZERS AND SUB-WOOFER VOLUME CONTROLS .
FUSE BLOCKS
See FUSE BOXES AND BLOCKS .
FUSE BOXES AND BLOCKS
FUSE BOX AND BLOCK 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
of hardware.
Broken, affecting
performance ............ A ............ Require replacement.
Broken, not affecting
performance ............ .. ........ No service suggested or
required.
Burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Burned, not affecting
performance ............ 2 ........... ( 1) Suggest repair or
replacement.
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.
Cover missing ........... C ... Require replacement of cover.
Cracked, affecting
performance ............ A .. Require repair or replacement.
Cracked, not affecting
performance ............ 1 .. Suggest repair or replacement.
Melted, affecting
performance ............ A ........ ( 1) Require replacement.

adjusters.
Seized .................. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.









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HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND
SEATS)
HEATING ELEMENT (DEFROSTER, DEFOGGER, ELECTRIC HEATER AND SEAT)
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
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.
Inoperative ............. A ........... ( 2) Require repair or
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 burned ........ A .. Require repair or replacement.
Wire lead conductors
exposed ................ B .. 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) - Inoperative includes intermittent operation or out of OEM
specification.









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HORNS AND SIRENS
HORN AND SIREN INSPECTION








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Condition Code Procedure

SEAT HEATERS
See
HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND SEATS) .
SECURITY ALARM SENSORS
SECURITY ALARM SENSOR INSPECTION








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Condition Code Procedure
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.
Connector broken ........ A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. B ........... ( 2) Require repair or
replacement. Further
inspection required.
Missing ................. C ............ Require replacement.
Resistance out of
specification .......... B .. Require repair or 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.
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) - Inoperative includes intermittent operation or out of OEM
specification.









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SIRENS

Valve Open ............................. 200 @ 1.212 (89 @ 30.89)\









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CYLINDER HEAD








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Application Specification
Maximum Warpage ................ .00075" Per 1" (.0191 mm Per 25 mm)\
Valve Seats
Intake Valve
Seat Angle ......................................... 44.25-44.75

Seat Width .............................. .040-.060" (1.0-1.5 mm)\
Maximum Seat Runout .............................. .003" (.08 mm)\
Exhaust Valve
Seat Angle ......................................... 44.25-44.75

Seat Width .............................. .060-.080" (1.5-2.0 mm)\
Maximum Seat Runout .............................. .003" (.08 mm)\
Valve Guides
Intake Valve
Valve Guide I.D.
3.9L & 5.2L ......................... .313-.314" (7.95-7.96 mm)\
5.9L ................................ .374-.375" (9.50-9.53 mm)\
Valve Stem-To-Guide Oil Clearance
Standard .............................. .001-.003" (.02-.08 mm)\
Wear Limit ................................. (1) .017" (.43 mm)
Exhaust Valve
Valve Guide I.D.
3.9L & 5.2L ......................... .313-.314" (7.95-7.98 mm)\
5.9L ................................ .374-.375" (9.50-9.53 mm)\
Valve Stem-To-Guide Oil Clearance
Standard .............................. .001-.003" (.02-.08 mm)\
Wear Limit ................................. ( 1) .017" (.43 mm)
( 1) - Specification applies to method obtained by rocking valve stem
in valve guide.









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CAMSHAFT ( 1)








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Application In. (mm)\
End Play
3.9L & 5.2L .................................. .002-.010 (.05-.25)\
5.9L ...................................... .002-.010 (.05-.25 mm)\
Camshaft Bearing I.D.
3.9L
No. 1 ................................. 2.000-2.001 (50.80-50.82)\
No. 2 ................................. 1.984-1.985 (50.39-50.42)\
No. 3 ................................. 1.953-1.954 (49.61-49.63)\
No. 4 ................................. 1.563-1.564 (39.70-39.73)\
5.2L & 5.9L
No. 1 ................................. 2.000-2.001 (50.80-50.82)\
No. 2 ................................. 1.984-1.985 (50.39-50.42)\
No. 3 ................................. 1.969-1.970 (50.01-50.04)\
No. 4 ................................. 1.953-1.954 (49.61-49.63)\
No. 5 ................................. 1.563-1.564 (39.70-39.73)\
Journal Diameter
3.9L
No. 1 ................................. 1.998-1.999 (50.75-50.77)\
No. 2 ................................. 1.982-1.983 (50.34-50.37)\
No. 3 ................................. 1.951-1.952 (49.56-49.58)\
No. 4 ................................. 1.561-1.562 (39.65-39.67)\
5.2L & 5.9L

cylinder head design and type of metal used.
Remove valve guide from cylinder head by pressing or tapping
on a stepped drift. See Fig. 8. Once valve guide is installed,
distance from cylinder head to top of valve guide must be checked.
This distance must be within specification.
Aluminum heads are often heated before installing valve
guide. Guide is sometimes chilled in dry ice before installation.
Combination of a heated head and chilled guide insures a tight guide
fit upon assembly. The new guide must be reamed to specification.
Fig. 8: Typical Valve Guide Remover & Installer
This Graphic For General Information Only
VALVES & VALVE SEATS
Valve Grinding
Valve stem O.D. should be measured in several areas to
indicate amount of wear. Replace valve if not within specification.
Valve margin area should be measured to ensure that valve can be
grounded. See Fig. 9.
Fig. 9: Measuring Valve Head Margin - Typical
This Graphic For General Information Only
If valve margin is less than specification, this will burn
the valves. Valve must be replaced. Due to minimum margin dimensions

during manufacture, some new type valves cannot be reground.
Resurface valve on proper angle specification using valve
grinding machine. Follow manufacturer's instructions for valve
grinding machine. Specifications may indicate a different valve face
angle than seat angle.
Measure valve margin after grinding. Replace valve if not
within specification. Valve stem tip can be refinished using valve
grinding machine.
Valve Lapping
During valve lapping of recent designed valves, be sure to
follow manufacturers recommendations. Surface hardening and materials
used with some valves do not permit lapping. Lapping process will
remove excessive amounts of the hardened surface.
Valve lapping is done to ensure adequate sealing between
valve face and seat. Use either a hand drill or lapping stick with
suction cup attached.
Moisten and attach suction cup to valve. Lubricate valve stem
and guide. Apply a thin coat of fine valve grinding compound between
valve and seat. Rotate lapping tool between the palms or with hand
drill.
Lift valve upward off the seat and change position often.
This is done to prevent grooving of valve seat. Lap valve until a
smooth polished seat is obtained. Thoroughly clean grinding compound
from components. Valve to valve seat concentricity should be checked.
See VALVE SEAT CONCENTRICITY.
CAUTION: Valve guides must be in good condition and free of carbon
deposits prior to valve seat grinding. Some engines contain
an induction hardened valve seat. Excessive material removal
will damage valve seats.
Valve Seat Grinding
Select coarse stone of correct size and angle for seat to be
ground. Ensure stone is true and has a smooth surface. Select correct
size pilot for valve guide dimension. Install pilot in valve guide.
Lightly lubricate pilot shaft. Install stone on pilot. Move stone off
and on the seat approximately 2 times per second during grinding
operation.
Select a fine stone to finish grinding operation. Grinding
stones with 30 and 60 degree angles are used to center and narrow the
valve seat as required. See Fig. 10.
Fig. 10: Adjusting Valve Seat Width - Typical
This Graphic For General Information Only
Valve Seat Replacement
Replacement of valve seat inserts is done by cutting out

the old insert and machining an oversize insert bore. Replacement
oversize insert is usually chilled and the cylinder head is sometimes
warmed. Valve seat is pressed into the head. This operation requires
specialized machine shop equipment.
Valve Seat Concentricity
Using dial gauge, install gauge pilot in valve guide.
Position gauge arm on the valve seat. Adjust dial indicator to zero.
Rotate arm 360 degrees and note reading. Runout should not exceed
specification.
To check valve-to-valve seat concentricity, coat valve face
lightly with Prussian Blue dye. Install valve and rotate it on valve
seat. If pattern is even and entire seat is coated at valve contact
point, valve is concentric with the seat.
REASSEMBLY
Valve Stem Installed Height
Valve stem installed height must be checked when new valves
are installed or when valves or valve seats have been ground. Install
valve in valve guide. Measure distance from tip of valve stem to
spring seat. See Fig. 11. Distance must be within specifications.
Fig. 11: Measuring Valve Stem Installed Height - Typical
This Graphic For General Information Only
Remove valve and grind valve stem tip if height exceeds
specification. Valve tips are surface hardened. DO NOT remove more