1999 DODGE RAM key battery

Apply light coat of engine oil on NEW .060" (1.5 mm) thick Copper
sealing washer. Install NEW Copper sealing washer on spray tip of fuel
injector. Engine oil is used to aid holding sealing washer in place.
Install new "O" ring on fuel injector. Apply small amount of engine
oil to "O" ring.
2) Ensure fuel inlet hole on side of fuel injector is
positioned toward injector connector tube. Install injector into
cylinder head bore using care not to allow injector tip to touch sides
of bore. Press fuel injector into cylinder head with finger pressure
only. Install fuel injector hold down clamp into shouldered bolt while
aligning slot in top of injector into groove in bottom of clamp.
Tighten opposite clamp bolt to specification. See TORQUE
SPECIFICATIONS.
3) Apply small amount of clean engine oil to NEW "O" ring.
Install "O" ring to fuel injector connector tube. Using finger
pressure only, press injector connector tube into cylinder head.
Connect and tighten high pressure fuel lines to specification. See
TORQUE SPECIFICATIONS.
NOTE: Fuel line fitting torque is important. Mating surfaces will
not seal if fuel line fitting is under or over-torqued.
4) To install remaining components, reverse removal
procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Bleed high-pressure fuel lines. See FUEL LINE BLEEDING under FUEL
SYSTEM.
FUEL INJECTION PUMP
CAUTION: High-pressure fuel lines must be clamped securely and routed
so they do not contact each other or any other components. DO
NOT weld or substitute high-pressure fuel lines. High
-pressure lines are same length and proper high-pressure fuel
line must be installed in specified area for proper engine
operation.
Removal
1) Disconnect negative battery cables. Clean fuel lines at
cylinder head and injection pump. Clean fuel injection pump and fuel
lines at side of pump. Disconnect 9-pin electrical connector at Fuel
Pump Control Module (FPCM). Place a rag around overflow valve to catch\
excess fuel. Remove overflow valve and disconnect fuel return line.
Remove banjo bolts and fuel supply line at side of injection pump and
top of fuel filter housing.
2) Remove all high pressure fuel lines, intake air tube,
accelerator pedal position sensor, air intake housing, engine oil
dipstick tube, wiring clips, electrical connectors at intake heaters,
and engine lifting bracket. Unscrew plastic access cap at front gear
cover. Remove injection pump gear-to-injection pump shaft nut and
washer.
3) Engine may be rotated by removing dust plug from
transmission adapter plate and installing Engine Barring Tool (Snap-On
SP371) in transmission adapter plate. See Fig. 9. Rotate engine until
keyway is at 12 o'clock 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

WARNING: Wait about 2 minutes after disconnecting negative battery
cable before servicing air bag system. System reserve
capacitor maintains air bag system voltage for about 2
minutes after battery is disconnected. Servicing air bag
system before 2 minutes may cause accidental air bag
deployment and possible personal injury.
REMOVAL & INSTALLATION
WARNING: All models are equipped with Air Bag Restraint System (ABRS).
See AIR BAG PRECAUTIONS before working on vehicle. Use
caution when working around steering column (air bag could
deploy).
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.
HORN PAD & STEERING WHEEL
Removal & Installation
1) Disable air bag system. See AIR BAG DISABLING. Ensure
steering wheel is in straight-ahead position. Remove nuts mounting air
bag module to steering wheel. Remove screws securing cruise control
switch to steering wheel (if equipped).
2) Disconnect wiring connectors. Remove air bag module and
cruise control switch assembly. Pry trim covers from back of steering
wheel and remove horn switch mounting screws. Disconnect horn wires.
Remove horn switch.
3) Remove steering wheel retaining nut. Reference mark
steering wheel and steering shaft. Using puller, remove steering
wheel. To install, reverse removal procedure. Align marks made during
removal. Tighten steering wheel retaining nut to specification.
STEERING COLUMN
Removal & Installation
1) Position front wheels straight ahead. Disconnect and
isolate negative battery cable. On column shift models, remove link
rod from bushing in shift lever. Discard bushing. On all models,
remove steering wheel using Puller (C-3428-B). See HORN PAD & STEERING\
WHEEL.
2) Remove steering column shaft-to-coupler retaining pin.
Push upper coupler shaft down into lower steering coupler. Remove dash
panel column cover. On column shift models, disconnect shift indicator
cable.
3) On all models, remove tilt lever (if equipped). Remove
upper and lower shroud. Remove lower fixed shroud. Disconnect
multifunction switch harness connector. Disconnect harness connectors
from ignition switch, key-in light, horn and cruise control (if
equipped).
4) Loosen upper support bracket nuts and allow column to drop
slightly. Remove upper fixed shroud. Disconnect wiring harness
retainers from column, and move harness to one side. Remove lower dash
panel. Remove lower steering column nuts. Remove column.
CAUTION: DO NOT reuse bushing in shift rod lever once shift rod is
removed. Always install a NEW bushing.
5) To install column, reverse removal procedure. Connect

Fig. 7: Positioning Column Lock Flag
Courtesy of Chrysler Corp.
LOCK CYLINDER
Removal
Disconnect and isolate negative battery cable. On tilt
columns, remove tilt lever. Remove upper and lower steering column
covers. Place shifter in Park (if vehicle has automatic transmission).\
With key inserted and ignition switch in RUN position, press on
retaining pin. See Fig. 8. Remove lock cylinder.
Installation
1) With key in lock cylinder, turn lock cylinder to RUN
position so retaining pin can be depressed. Install lock cylinder in
ignition switch (aligning slot) until retaining pin engages. Turn key
to OFF or LOCK position. Pull on lock cylinder to ensure retaining pin
is retained in ignition switch and cylinder will not come out.
2) Install upper and lower steering column covers. Tighten
screws to 17 INCH lbs. (2 N.m). Install tilt lever (if equipped).
Connect negative battery cable. Check for proper operation of ignition
switch in all positions. Check for proper steering wheel lock
operation. Check for proper automatic shift lock operation.

* Charging System
* Cruise Control System
* Intake Manifold Air Heater
* Tachometer
* Torque Convertor Clutch Engagement (A/T Only)
* Transmission Overdrive Solenoid (A/T Only) Components are
grouped into 2 categories. The first category covers INPUT
DEVICES, which control or produce voltage signals monitored
by the PCM. The second category covers OUTPUT SIGNALS, which
are components controlled by the PCM. See PCM INPUT SIGNALS
and ECM/PCM OUTPUT SIGNALS.
ECM INPUT SIGNALS
Accelerator Pedal Position Sensor (APPS)
APPS sensor is mounted on top left of engine. See Fig. 2.
Sensor provides DC voltage input signal to Engine Control Module (ECM)\
to indicate throttle position. On previous engines, there were
linkages between accelerator pedal, throttle position sensor and
injection pump. On this engine, no linkage exists between accelerator
pedal and injection pump. ECM uses input signals from APPS sensor to
determine proper fuel delivery. ECM also outputs this signal to PCM.
Battery Voltage
Battery voltage input signal provides operating voltage to
Engine Control Module (ECM). This input signal keeps ECM memory alive
and informs ECM what generator output voltage is when engine is
running. ECM memory is used to store Diagnostic Trouble Codes (DTCs),
store APPS sensor voltages from previous key cycles and provide a
speed control adaptive memory.
Camshaft Position Sensor (CMP)
Camshaft Position (CMP) sensor is a hall effect sensor (0-5
volts switched), located below injection pump in rear face of timing
gear cover. Sensor is not used for fuel control. Sensor is used only
for diagnostic purposes.
CCD Bus Circuits
These circuits are connected between Engine Control Module
(ECM) and Powertrain Control Module (PCM) to allow communication
between modules.
Crankshaft Position Sensor (CKP)
Crankshaft Position (CKP) sensor delivers input signal (35
tooth wheel with gap) to Engine Control Module (ECM) to indicate
engine speed and crankshaft position. ECM uses CKP signal along with
other input signals for controlling injector firing sequence and
timing. Sensor is located below fuel transfer pump, on side of engine
block. See Fig. 2.
Data Link Connector (DLC)
Data Link Connector (DLC) provides an input signal to Engine
Control Module (ECM) when using scan tool to retrieve Diagnostic
Trouble Codes (DTCs) from ECM. Input signal may also be used when
performing various tests on the ECM and electronic control system.
Data link connector is a 16-pin connector located at lower edge of
driver's side of instrument panel, just above accelerator pedal.
Engine Coolant Temperature (ECT) Sensor
Engine coolant temperature sensor delivers input signal to
Engine Control Module (ECM) to indicate engine coolant temperature.
ECM uses input signal for controlling fuel control and timing. Engine
coolant temperature sensor is located on front of head, near

located in power distribution center at driver's side front corner of
engine compartment, near the battery. Automatic Shutdown (ASD) relay
may also be referred to as Auto Shutdown (ASD) relay.
Battery Temperature Sensor
Battery temperature sensor delivers input signal to
Powertrain Control Module (PCM) to indicate the battery temperature.
PCM uses battery temperature input to modify rate of output from the
charging system. Battery temperature sensor is snapped into battery
tray below driver's side battery.
Battery Voltage
Battery voltage input signal provides operating voltage to
Powertrain Control Module (PCM). This input signal keeps PCM memory
alive and informs PCM what generator output voltage is when engine is
running. PCM memory is used to store Diagnostic Trouble Codes (DTCs),
store APPS sensor voltages from previous key cycles and provide a
speed control adaptive memory.
Brake Switch
Brake switch delivers input signal to Powertrain Control
Module (PCM) to indicate when brakes are applied. PCM uses input
signal for controlling cruise control system and transmission torque
converter clutch operation on A/T models. Brake switch is located near
top of brake pedal and may also be referred to as brakelight switch.
CKP Sensor
Crankshaft Position (CKP) sensor delivers input signal (35
tooth wheel with gap) to Engine Control Module (ECM) to indicate
engine speed and crankshaft position. ECM uses CKP signal along with
other input signals for controlling injector firing sequence and
timing. Sensor is located below fuel transfer pump, on side of engine
block. See Fig. 2.
Cruise Control System Switches
Cruise control system functions, controlled by momentary
contact switches, are monitored through multiplexed input signal to
Powertrain Control Module (PCM). Resistance monitored at this input
signal, in conjunction with the length of time the PCM measures the
resistance, determines which switch feature has been selected.
Data Link Connector (DLC)
Data Link Connector (DLC) provides an input signal to
Powertrain Control Module (PCM) when using scan tool to retrieve
Diagnostic Trouble Codes (DTCs) from PCM. Input signal may also be
used when performing various tests on the PCM and electronic control
system. DLC is a 16-pin connector located at lower edge of driver's
side of instrument panel, just above accelerator pedal.
Fuel Level Sensor
The Powertrain Control Module (PCM) sends a 5-volt signal to
the fuel level sensor. The fuel level sensor will return a signal to
PCM. This signal is used for fuel gauge operation and to prevent
setting a false misfire or fuel system trouble codes. If fuel level is
less than 15 percent, PCM will not set code.
Ignition Sense
Ignition switch position input to Powertrain Control Module
(PCM). PCM uses input to determine proper output functions, including
cruise control, generator output, sensor supply and transmission
functions.
Transmission Speed Sensor (A/T Models)