1999 DODGE RAM check engine light

next step. If scan tool does not display brake pedal PRESSED and
RELEASED, go to NTC-1: BRAKE SWITCH SENSE.
4) Turn S/C on. On A/T models, move gear selector to Drive.
If scan tool displays park neutral switch D/R, go to next step. If
scan tool does not display park neutral switch D/R, go to FTC P1899:
PARK/NEUTRAL POSITION SWITCH STUCK IN PARK OR IN GEAR under DIAGNOSTIC
TESTS.
5) On all models, using scan tool, actuate S/C vent solenoid.
Using a 12-volt test light, backprobe S/C brake switch output circuit
at S/C servo connector terminal No. 3 (Dark Blue/Red wire). If test
light is illuminated and bright, go to next step. If test light is dim
or is not illuminated, go to NTC-1: BRAKE SWITCH SENSE.
6) Start engine and let idle for one minute. Turn engine off.
Turn ignition on (engine off). Using scan tool, actuate S/C servo
solenoids. If throttle opens and closes, go to NTC-2: CHECKING FOR
SPEED CONTROL DENIED MESSAGE. If throttle does not open and close,
inspect throttle cable and linkage. Check vacuum supply. See VACUUM
SUPPLY under COMPONENT TESTS. Repair as necessary. Perform TEST VER-4A
under VERIFICATION TESTS.
7) While observing scan tool, press CANCEL switch several
times. If scan tool displays PRESSED and RELEASED, go to next step. If
scan tool does not display PRESSED and RELEASED, replace CANCEL
switch. Perform TEST VER-4A under VERIFICATION TESTS.
8) Turn ignition off. Disconnect S/C servo connector. Using
an ohmmeter, check resistance of ground circuit at S/C servo connector
terminal No. 4 (Black wire). If resistance is 5 ohms or more, repair
open ground circuit. Perform TEST VER-4A under VERIFICATION TESTS. If
resistance is less than 5 ohms, go to next step.
9) Reconnect S/C servo connector. Turn ignition and S/C on.
While observing scan tool, press SET switch several times. If scan
tool displays PRESSED and RELEASED, go to next step. If scan tool does
not display PRESSED and RELEASED, replace SET switch. Perform TEST
VER-4A under VERIFICATION TESTS.
10) Turn ignition off. Disconnect S/C servo connector.
Inspect terminals. If any terminal is damaged, pushed out or miswired,
repair as necessary. Perform TEST VER-4A under VERIFICATION TESTS. If
terminals are okay, go to next step.
11) Disconnect S/C servo connector. Disconnect PCM
connectors. Inspect connectors. Clean or repair as necessary. Using an
ohmmeter, check resistance of S/C vacuum solenoid control circuit
between PCM connector C3, terminal No. 4 and S/C servo connector
terminal No. 1 (Tan/Red wire). If resistance is 5 ohms or more, repair\
open circuit. Perform TEST VER-4A under VERIFICATION TESTS. If
resistance is less than 5 ohms, go to next step.
12) Turn S/C on. While observing scan tool, press COAST
switch several times. If scan tool displays PRESSED and RELEASED, go
to next step. If scan tool does not display PRESSED and RELEASED,
replace COAST switch. Perform TEST VER-4A under VERIFICATION TESTS.
13) Using an ohmmeter, check resistance of S/C vent solenoid
control circuit between PCM connector C3, terminal No. 5 and S/C servo
connector terminal No. 2 (Light Green/Red wire). If resistance is 5
ohms or more, repair open circuit. Perform TEST VER-4A under
VERIFICATION TESTS. If resistance is less than 5 ohms, replace S/C
servo. Perform TEST VER-4A under VERIFICATION TESTS.
NTC-1: BRAKE SWITCH SENSE
Possible Causes:
* Ground circuit open.
* Defective brake switch.
* Brake switch sense circuit open or shorted.
* Defective PCM.

(8) - One used on vehicles with light-duty emissions. Two used on 

vehicles with heavy-duty emissions. 

(
9) - Used on vehicles with heavy-duty emissions. 

(
10 ) - Two catalytic converters are required. 

(
11 ) - Four sensors used on vehicles with medium-duty emissions. 

Two sensors used on vehicles with heavy-duty emissions. 










\









\









\









\









\









\









\





\f

ABBREVIATIONS
ABBREVIATION DEFINITIONS








\









\









\









\









\









\







Abbreviation Definition
AIH ................................... Air Intake Heaters
AIH-TS ............................ AIH Temperature Sensor
AP ............................. Air Pump Injection System
AP-CKV .................................... AP Check Valve
AP-RV .................................... AP Relief Valve
BP/EGR ........................... Backpressure EGR System
BP/EGR-BPT ................ BP/EGR Backpressure Transducer
CCV ................................ Crankcase Ventilation
CEC ......................... Computerized Engine Controls
CNG ............................... Compressed Natural Gas
EFI ............................ Electronic Fuel Injection
EGR-CKV .................................. EGR Check Valve
EVAP ............................. Fuel Evaporative System
EVAP-CVV ........................ EVAP Canister Vent Valve
EVAP-LDP ........................ EVAP Leak Detection Pump
EVAP-LDPF ................ EVAP Leak Detection Pump Filter
EVAP-PRRV ............ EVAP Pressure Relief Rollover Valve
EVAP-PSOL ............................ EVAP Purge Solenoid
EVAP-VC .............................. EVAP Vapor Canister
EVAP-VV ........................... EVAP Ventilation Valve
FR ................................... Fillpipe Restrictor
HO2S ................................ Heated Oxygen Sensor
MIL .......................... Malfunction Indicator Light
PCV ....................... Positive Crankcase Ventilation
SFI .................. Sequential Multiport Fuel Injection
SPK ....................................... Spark Controls
SPK-CC ........................... SPK Computer Controlled
TWC ........................ Three-Way Catalytic Converter









\









\









\









\









\









\







EARLY FUEL EVAPORATION (EFE)
The EFE valve is actuated by either a vacuum actuator or a
bimetal spring (heat-riser type). The EFE valve is closed when engine
is cold. The closed valve restricts exhaust gas flow from the exhaust
manifold. This forces part of the exhaust gas to flow up through a
passage below the carburetor. As the exhaust gas quickly warms the
intake mixture, distribution is improved. This results in better cold
engine driveability, shorter choke periods and lower emissions.
Ensure EFE valve in exhaust manifold is not frozen or rusted
in a fixed position. On vacuum-actuated EFE system, check EFE thermal
vacuum valve and check valve(s). Also check for proper vacuum hose
routing. See Fig. 15.
Fig. 15: Typical Vacuum-Actuated EFE System
Courtesy of General Motors Corp.
EMISSION MAINTENANCE REMINDER LIGHT (EMR) (IF EQUIPPED)

If equipped, the EMR light (some models may use a reminder
flag) reminds vehicle operator that an emission system maintenance is
required. This indicator is activated after a predetermined
time/mileage.
When performing a smog check inspection, ensure EMR indicator
is not activated. On models using an EMR light, light should glow when
ignition switch is turned to ON position and should turn off when
engine is running.
If an EMR flag is present or an EMR light stays on with
engine running, fail vehicle and service or replace applicable
emission-related components. To reset an EMR indicator, refer to
appropriate MAINTENANCE REMINDER LIGHTS in the MAINTENANCE section.
MALFUNCTION INDICATOR LIGHT (MIL)
The Malfunction Indicator Light (MIL) is used to alert
vehicle operator that the computerized engine control system has
detected a malfunction (when it stays on all the time with engine
running). On some models, the MIL may also be used to display trouble
codes.
As a bulb and system check, malfunction indicator light will
glow when ignition switch is turned to ON position and engine is not
running. When engine is started, light should go out.

2) Ensure journal diameter, taper and out-of-round are within
specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table
under ENGINE SPECIFICATIONS. Upper main bearings contain oil holes,
while lower bearings installed in main bearing cap do not.
3) Apply light coat of engine oil to threads before
tightening bolt to specification. See TORQUE SPECIFICATIONS table.
Ensure oil clearance and end play are within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table.
CAUTION: Crankshaft journal grinding should not exceed .012" (.30 mm)
under standard size. DO NOT grind thrust surfaces of No. 3
main bearing. Final paper or cloth polishing after regrind
must be done in same direction as engine rotation.
Thrust Bearing
Thrust bearing is located on No. 3 main bearing. Replace
thrust bearing if crankshaft end play is not within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE
SPECIFICATIONS.
NOTE: Cylinder bore should be measured at room temperature of 70
F
(21C).
Cylinder Block
1) Check cylinder bore, out-of-round and taper. Measure
cylinder bore diameter below top surface of cylinder bore, middle of
bore and bottom of cylinder bore. Bore cylinder block if bore diameter
is not within specification. See CYLINDER BLOCK table under ENGINE
SPECIFICATIONS.
NOTE: Cylinder block is marked to indicate oversize valve lifters.
See SPECIAL ENGINE MARKS.
2) Check valve lifter bore diameter. Check for scoring. If
scoring exists or lifter bore diameter is not within specification,
ream cylinder block bore for next oversize valve lifter. See VALVE
LIFTERS table under ENGINE SPECIFICATIONS.
ENGINE OILING
ENGINE LUBRICATION SYSTEM
System has a rotor-type oil pump and full-flow oil filter.
Oil is forced by pump through a series of oil passages in engine to
provide lubrication to engine components. Oil is supplied to rocker
assembly through hollow push rods. Push rods are fed oil from lifters.
See Fig. 17 .
Crankcase Capacity
On 3.9L, oil capacity with oil filter is 4.0 qts. (3.8L). On
5.2L and 5.9L, oil capacity with oil filter is 5.0 qts. (4.7L).
Oil Pressure
Oil pressure is 6 psi (.4 kg/cm
) at idle and 30-80 psi (2.1-
5.6 kg/cm) at 3000 RPM with engine at normal operating temperature.


EN G IN E O VER HAU L P R O CED URES - G EN ER AL IN FO RM ATIO N

1999 D odge P ic ku p R 1500
Engine Overhaul Procedures - General Information
ALL PISTON ENGINES
* PLEASE READ THIS FIRST *
Examples used in this article are general in nature and do
not necessarily relate to a specific engine or system. Illustrations
and procedures have been chosen to guide mechanic through engine
overhaul process. Descriptions of processes of cleaning, inspection,
assembly and machine shop practice are included.
Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and specifications
for the vehicle being repaired.
ENGINE IDENTIFICATION
The engine may be identified from its Vehicle Identification
Number (VIN) stamped on a metal tab. Metal tab may be located in
different locations depending on manufacturer. Engine identification
number or serial number is located on cylinder block. Location varies
with manufacturer.
INSPECTION PROCEDURES
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
GENERAL
Engine components must be inspected to meet manufacturer's
specifications and tolerances during overhaul. Proper dimensions and
tolerances must be met to obtain proper performance and maximum engine
life.
Micrometers, depth gauges and dial indicator are used for
checking tolerances during engine overhaul. Magnaflux, Magnaglo, dye-
check, ultrasonic and x-ray inspection procedures are used for parts
inspection.
MAGNETIC PARTICLE INSPECTION
Magnaflux & Magnaglo
Magnaflux is an inspection technique used to locate material
flaws and stress cracks. The part in question is subjected to a strong
magnetic field. The entire part, or a localized area, can be
magnetized. The part is coated with either a wet or dry material that
contains fine magnetic particles.
Cracks which are outlined by the particles cause an
interruption in the magnetic field. The dry powder method of Magnaflux
can be used in normal light. A crack will appear as an obvious bright
line.
Fluorescent liquid is used in conjunction with a blacklight
in a second Magnaflux system called Magnaglo. This type of inspection
demands a darkened room. The crack will appear as a glowing line in
this process. Both systems require complete demagnetizing upon

completion of the inspection. Magnetic particle inspection applies to
ferrous materials only.
PENETRANT INSPECTION
Zyglo
The Zyglo process coats the material with a fluorescent dye
penetrant. The part is often warmed to expand cracks that will be
penetrated by the dye. When the coated part is subjected to inspection
with a blacklight, a crack will glow brightly. Developing solution
is often used to enhance results. Parts made of any material, such as
aluminum cylinder heads or plastics, may be tested using this process.
Dye Check
Penetrating dye is sprayed on the previously cleaned
component. Dye is left on component for 5-45 minutes, depending upon
material density. Component is then wiped clean and sprayed with a
developing solution. Surface cracks will show up as a bright line.
ULTRASONIC INSPECTION
If an expensive part is suspected of internal cracking,
Ultrasonic testing is used. Sound waves are used for component
inspection.
X-RAY INSPECTION
This form of inspection is used on highly stressed
components. X-ray inspection maybe used to detect internal and
external flaws in any material.
PRESSURE TESTING
Cylinder heads can be tested for cracks using a pressure
tester. Pressure testing is performed by plugging all but one of the
holes in the head and injecting air or water into the open passage.
Leaks are indicated by the appearance of wet or damp areas when using
water. When air is used, it is necessary to spray the head surface
with a soap solution. Bubbles will indicate a leak. Cylinder head may
also be submerged in water heated to specified temperature to check
for cracks created during heat expansion.
CLEANING PROCEDURES
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
GENERAL
All components of an engine do not have the same cleaning
requirements. Physical methods include bead blasting and manual
removal. Chemical methods include solvent blast, solvent tank, hot
tank, cold tank and steam cleaning of components.
BEAD BLASTING
Manual removal of deposits may be required prior to bead
blasting, followed by some other cleaning method. Carbon, paint and

NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
REMOVAL
Remove intake and exhaust manifolds and valve cover. Cylinder
head and camshaft carrier bolts (if equipped), should be removed only
when the engine is cold. On many aluminum cylinder heads, removal
while hot will cause cylinder head warpage. Mark rocker arm or
overhead cam components for location.
Remove rocker arm components or overhead cam components.
Components must be installed in original location. Individual design
rocker arms may utilize shafts, ball-type pedestal mounts or no rocker
arms. For all design types, wire components together and identify
according to the corresponding valve. Remove cylinder head bolts.
Note length and location. Some applications require cylinder head
bolts be removed in proper sequence to prevent cylinder head damage.
See Fig. 1 . Remove cylinder head.
Fig. 1: Typical Cylinder Head Tightening or Loosening Sequence
This Graphic For General Information Only
INSTALLATION
Ensure all surfaces and head bolts are clean. Check that head
bolt holes of cylinder block are clean and dry to prevent block damage
when bolts are tightened. Clean threads with tap to ensure accurate
bolt torque.
Install head gasket on cylinder block. Some manufacturer's
may recommend sealant be applied to head gasket prior to installation.
Note that all holes are aligned. Some gasket applications may be
marked so certain area faces upward. Install cylinder head using care
not to damage head gasket. Ensure cylinder head is fully seated on
cylinder block.
Some applications require head bolts be coated with sealant
prior to installation. This is done if head bolts are exposed to water
passages. Some applications require head bolts be coated with light
coat of engine oil.