1999 DODGE RAM cooling

1) Partially drain cooling system. Engine coolant temperature
sensor is located on front of intake manifold, near inside of
generator and contains a Tan/Black wire and a Black/Light Blue wire in
the electrical connector.
2) On 3.9L, remove engine cover and air cleaner housing from
inside of vehicle for access to engine coolant temperature sensor. On
5.2L and 5.9L, engine coolant temperature sensor may be serviced from
front of vehicle without removing engine cover and air cleaner
housing.
3) On all models, disconnect electrical connector at engine
coolant temperature sensor. It may be necessary to use a coat hanger
and fabricate an "L" shaped tool about 8" (203 mm) long to disconnect
electrical connector by placing hook part of tool under electrical
connector and pulling electrical connector upward from engine coolant
temperature sensor. Remove engine coolant temperature sensor.
Installation
To install, reverse removal procedure. Tighten engine coolant
temperature sensor to specification. See TORQUE SPECIFICATIONS. Fill
cooling system.
FUEL LEVEL SENSOR
Removal & Installation
See FUEL LEVEL SENSOR under FUEL SYSTEM.
INTAKE AIR TEMPERATURE (IAT) SENSOR
NOTE: Intake air temperature sensor may also be referred to as
intake manifold air temperature sensor.
Removal & Installation (Dakota, Durango & Ram Pickup)
1) IAT sensor is screwed into the intake manifold. See Fig. 4
, 5 or 6. Remove air inlet duct or air cleaner assembly for access to
IAT sensor if necessary. Disconnect electrical connector at IAT
sensor. Remove IAT sensor from intake manifold.
2) To install, reverse removal procedure. Tighten IAT sensor
to specification. See TORQUE SPECIFICATIONS.
Removal & Installation (Ram Van & Ram Wagon)
1) IAT sensor is screwed into the intake manifold. See Fig. 5
. On 3.9L, remove engine cover and air cleaner housing from inside of
vehicle for access to IAT sensor. On 5.2L and 5.9L, IAT sensor may be
serviced from front of vehicle without removing engine cover and air
cleaner housing.
2) On all models, disconnect electrical connector at IAT
sensor. Remove IAT sensor from intake manifold. To install, reverse
removal procedure. Tighten IAT sensor to specification. See TORQUE
SPECIFICATIONS.
Fig. 4: Locating Intake Air Temperature (IAT) Sensor (Dakota 2.5L)
Courtesy of Chrysler Corp.


C - S PEC IF IC ATIO NS

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Service & Adjustment Specifications - Trucks
Caravan, Dakota, Durango, Ram Pickup, Ram Van, Ram Wagon,
Town & Country, Voyager
INTRODUCTION
Use this article to quickly find specifications related to
servicing and on-vehicle adjustments. This is a quick-reference
article to use when you are familiar with an adjustment procedure and
only need a specification.
CAPACITIES
BATTERY SPECIFICATIONS








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Application & Group Cold Cranking Amp Hr.
Amps Rating
Caravan
2.4L (Group 34) ....................... 600 ................. 66\
3.0L (Group 34) ....................... 500 ................. 60\
3.3L (Group 34) ....................... 500 ................. 60\
3.8L
Std. Battery (Group 34) .............. 600 ................. 66\
Opt. Battery (Group 34) .............. 685 ................. 72\
Dakota & Durango
Std. Battery (Group 27) ............... 600 ................. 66\
Opt. Battery (Group 27) ............... 750 ................. 75\
Ram Pickup
3.9L, 5.2L & 5.9L (Gasoline)
Std. Battery (Group 27) .............. 600 ................. 66\
Opt. Battery (Group 27) .............. 750 ................. 75\
5.9L (Diesel) ( 2) & 8.0L .............. 750 ................. 75
Ram Van & Ram Wagon
Std. Battery (Group 27) ............... 600 ................. 66\
Opt. Battery (Group 27) ............... 750 ................. 75\
Town & Country
3.3L (Group 34) ....................... 500 ................. 60\
3.8L
Std. Battery (Group 34) .............. 600 ................. 66\
Opt. Battery (Group 34) .............. 685 ................. 72\
Voyager
2.4L (Group 34) ....................... 600 ................. 66\
3.0L (Group 34) ....................... 500 ................. 60\
3.3L (Group 34) ....................... 500 ................. 60\
( 1) - Information is not available from manufacturer.
( 2) - Two batteries.









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FLUID CAPACITIES (CARAVAN, TOWN & COUNTRY, & VOYAGER)








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Application ( 1) Quantity
Crankcase (Includes Filter) ( 2)
2.4L, 3.0L, 3.3L & 3.8L .......................... 4.5 Qts. (4.3L)\
Cooling System ( 3)

2.4L ........................................... 11.2 Qts. (10.6L)\
3.0L ........................................... 13.0 Qts. (12.3L)\
3.3L & 3.8L .................................... 13.2 Qts. (12.5L)\
Automatic Transaxle (Mopar ATF Plus Type 7176)
3-Speed
Drain & Refill .............................. (4) 4.0 Qts. (3.8L)
Dry Refill ...................................... 8.5 Qts. (8.0L)\
4-Speed
Drain & Refill .............................. ( 4) 4.0 Qts. (3.8L)
Dry Refill ...................................... 9.1 Qts. (8.6L)\
Overrunning Clutch
(Mopar ATF Plus Type 7176 - AWD Models) ...................... ( 5)
Power Steering Fluid ( 6) ............................ 1.7 Pts. (.8L)
Power Transfer Unit
(SAE 80W-90/API GL-5 - AWD Models) .............. 1.2 Qts. (1.14L\
)
Rear Differential
(SAE 80W-90/API GL-5 - AWD Models) ( 5) ....................... ( 7)
( 1) - Approximate quantity listed.
( 2) - Use an API energy conserving engine oil that is certified for
gasoline engines on all engines except 3.3L flex-fuel models.
On 3.3L flex-fuel models, use Mopar Flex-Fuel 5W-30 engine oil
or an equivalent that meets Chrysler Standard MS-9214. Proper
engine oil MUST BE used to prevent engine damage. The 3.3L
flex-fuel model may be referred to as Flex-Fuel Vehicle (FFV)
model and is used in all vehicles except California emission
vehicles. Flex-fuel model may be also referred to as an E85
application and may be identified by label attached to inside of
gasoline filler door.
( 3) - Quantity includes heater and coolant recovery tank. Add 2 qts.
(1.9L) if equipped with rear heater.
( 4) - Add this amount of fluid. Start engine and shift transaxle
through all gears and back to Park. Add additional fluid to
bring fluid level to 1/8" below the ADD mark on dipstick.
Recheck fluid level with transaxle at normal operating
temperature. Adjust fluid level so fluid level is within the
HOT range dipstick.
( 5) - An overrunning clutch is bolted on front of rear differential,
between torque tube for drive shaft and rear differential.
Overrunning clutch contains a separate reservoir from rear
differential. Ensure fluids are checked at appropriate
component, as different types of fluids are used. Fluid capacity
is not available from manufacturer.
( 6) - Use only Mopar power steering fluid. DO NOT use automatic
transmission fluid.
( 7) - Capacity is not available from manufacturer. Fill unit until
fluid level is even with bottom of filler plug hole.









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FLUID CAPACITIES (DAKOTA)








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Application ( 1) Quantity
Crankcase (Includes Filter) ( 2)
2.5L ............................................. 4.5 Qts. (4.3L)\
3.9L ............................................. 4.0 Qts. (3.8L)\
5.2L & 5.9L ...................................... 5.0 Qts. (4.7L)\
Cooling System (Includes Heater)
2.5L ............................................. 9.8 Qts. (9.3L)\
3.9L ........................................... 14.0 Qts. (13.2L)\
5.2L & 5.9L .................................... 14.3 Qts. (13.5L)\
Automatic Transmission
(Mopar ATF Plus Type 7176)

Drain & Refill .............................. (3) 1.5 Qts. (1.4L)
Dry Refill ....................... ( 4) 10.0-11.5 Qts. (9.5-10.8L)
Manual Transmission ( 5)
AX 15 (SAE 75W-90/API GL-5) 2.5L & 3.9L .......... 3.3 Qts. (3.1L\
)
NV 3500 (Mopar M/T Lube, P/N 4761526) 5.2L ....... 2.1 Qts. (2.0L\
)
Front Differential (SAE 80W-90/API GL-5) ........... 3.0 Pts. (1.4L\
)
Rear Differential (SAE 80W-90/API GL-5) ( 6)
8 1/4" Ring Gear ( 7) ............................. 4.4 Pts. (2.1L)
9 1/4" Ring Gear ( 7) ............................. 4.8 Pts. (2.3L)
Power Steering Fluid ( 8)
2WD ............................................... 1.7 Pts. (.8L)\
4WD .............................................. 2.5 Pts. (1.2L)\
Transfer Case (Mopar ATF Plus Type 7176) ........... 2.5 Pts. (1.2L\
)
( 1) - Approximate quantity listed.
( 2) - Use an API energy conserving engine oil that is certified for
gasoline engines.
( 3) - Add this amount of fluid. Start engine and shift transmission
through all gears and back to Neutral. Add additional fluid to
bring fluid level to the MIN mark on dipstick. Recheck fluid
level with transmission at normal operating temperature. Adjust
fluid level to MAX mark on dipstick. Approximate drain and
refill capacity is 4.0 qts. (3.8L).
( 4) - Quantity may vary by type of oil cooler and oil cooler lines.
( 5) - Verify type of transmission used before servicing. The AX 15
uses a flywheel housing bolted to the front of the transmission.
The NV 3500 uses a flywheel housing which is an integral part of
the transmission housing.
( 6) - Models with Trac-Lok limited slip differential must have 5 ozs.
(.15L) of Mopar Trac-Lok Friction Modifier added if lubricant is\
changed.
( 7) - Rear differential may be identified by number of bolts on rear
cover. The 8 1/4" ring gear has 10 bolts on rear cover and 9
1/4" ring gear has 12 bolts on rear cover.
( 8) - Use only Mopar power steering fluid. DO NOT use automatic
transmission fluid.









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FLUID CAPACITIES (DURANGO)








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Application ( 1) Quantity
Crankcase (Includes Filter) ( 2)
3.9L ............................................. 4.0 Qts. (3.8L)\
5.2L & 5.9L ...................................... 5.0 Qts. (4.7L)\
Cooling System (Includes Heater)
3.9L ........................................... 14.0 Qts. (13.2L)\
5.2L & 5.9L .................................... 14.3 Qts. (13.5L)\
Automatic Transmission
(Mopar ATF Plus Type 7176)
Drain & Refill .............................. ( 3) 1.5 Qts. (1.4L)
Dry Refill ....................... ( 4) 10.0-11.5 Qts. (9.5-10.8L)
Front Differential
(SAE 80W-90/API GL-5) ............................. 3.0 Pts. (1.4L\
)
Rear Differential
(SAE 80W-90/API GL-5) ( 5)
8 1/4" Ring Gear ( 6) ............................ 4.4 Pts. (2.1L)
9 1/4" Ring Gear ( 6) ............................ 4.8 Pts. (2.3L)
Power Steering Fluid ( 7) ........................... 2.5 Pts. (1.2L)
Transfer Case (Mopar ATF Plus Type 7176) ( 8)
NV 231 & NV 231HD ................................ 2.5 Pts. (1.2L)\
NV 242 ........................................... 3.0 Pts. (1.4L)\

(1) - Approximate quantity listed.
( 2) - Use an API energy conserving engine oil that is certified for
gasoline engines.
( 3) - Add this amount of fluid. Start engine and shift transmission
through all gears and back to Neutral. Add additional fluid to
bring fluid level to the MIN mark on dipstick. Recheck fluid
level with transmission at normal operating temperature. Adjust
fluid level to MAX mark on dipstick. Approximate drain and
refill capacity is 4.0 qts. (3.8L).
( 4) - Quantity may vary by type of oil cooler and oil cooler lines.
( 5) - Models with Trac-Lok limited slip differential must have 5 ozs.
(.15L) of Mopar Trac-Lok Friction Modifier added if lubricant is\
changed.
( 6) - Rear differential may be identified by number of bolts on rear
cover. The 8 1/4" ring gear has 10 bolts on rear cover and 9
1/4" ring gear has 12 bolts on rear cover.
( 7) - Use only Mopar power steering fluid. DO NOT use automatic
transmission fluid.
( 8) - Transfer case may be identified by model number stamped on
identification tag on rear of transfer case, just above filler
plug.









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FLUID CAPACITIES (RAM PICKUP)








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Application ( 1) Quantity
Crankcase (Includes Filter) ( 2)
3.9L ............................................. 4.0 Qts. (3.8L)\
5.2L & 5.9L (Gasoline) ........................... 5.0 Qts. (4.7L\
)
5.9L (Diesel) .................................. 11.0 Qts. (10.4L\
)
8.0L ............................................. 7.0 Qts. (6.6L)\
Cooling System (Includes Heater)
3.9L, 5.2L & 5.9L (Gasoline) ................... 20.0 Qts. (18.9L\
)
5.9L (Diesel) .................................. 24.0 Qts. (22.7L\
)
8.0L ........................................... 26.0 Qts. (24.6L)\
Automatic Transmission
(Mopar ATF Plus Type 7176)
42RE (3.9L)
Drain & Refill .............................. ( 3) 1.5 Qts. (1.4L)
Dry Refill ........................ ( 4) 8.5-11.0 Qts. (8.0-10.4L)
46RE (3.9L, 5.2L & 5.9L Gasoline)
Drain & Refill .............................. ( 3) 1.5 Qts. (1.4L)
Dry Refill ........................ ( 4) 9.5-11.5 Qts. (8.9-10.8L)
47RE (5.9L Diesel & 8.0L)
Drain & Refill .............................. ( 3) 1.5 Qts. (1.4L)
Dry Refill ...................... ( 4) 14.5-16.5 Qts. (13.7-15.6L)
Manual Transmission ( 5)
NV 3500 (Mopar M/T Lube,
P/N 4761526 - 3.9L & 5.2L) ...................... 2.1 Qts. (2.0L)\
NV 4500 (Mopar M/T Lube,
P/N 4637579) ( 6) - 5.9L
(Gas & Diesel) & 8.0L .......................... 4.0 Qts. (3.8L\
)
NV 5600 (Mopar M/T Lube,
P/N 4761526) ( 6) ............................... 4.75 Qts. (4.5L)
Front Differential (SAE 80W-90/API GL-5)
Dana 44 (Model 216 - 1500 & 2500) ................ 4.8 Pts. (2.3L\
)
Dana 60 (Model 248 - 2500 & 3500) ................ 7.6 Pts. (3.6L\
)
Rear Differential
9 1/4" Ring Gear
(SAE 75W-90/API
GL-5 - 1500 & 2500) ( 7) ........................ 4.8 Pts. (2.3L)
Dana 60 (Model 248)

Cooling System (Includes Heater)
3.9L ........................................... 14.6 Qts. (13.8L)\
5.2L ........................................... 16.5 Qts. (15.6L)\
5.9L
With Rear Heater .............................. 16.0 Qts. (15.1L)\
Without Rear Heater ........................... 15.0 Qts. (14.2L)\
Automatic Transmission (Mopar ATF Plus Type 7176)
32RH (3.9L)
Drain & Refill .............................. (3) 1.5 Qts. (1.4L)
Dry Refill .......................... ( 4) 8.5-8.8 Qts. (8.0-8.3L)
46RE (5.2L & 5.9L)
Drain & Refill .............................. ( 3) 1.5 Qts. (1.4L)
Dry Refill ...................... ( 4) 11.5-11.7 Qts. (10.8-11.1L)
Power Steering Fluid ( 5) ........................... 2.7 Pts. (1.3L)
Rear Differential
Dana 60
(Model 248 - SAE 90/API GL-5) ( 6)( 7) ............ 6.3 Pts. (2.9L)
8 1/4" & 9 1/4" Ring Gear
(SAE 80W-90/API GL-5) ( 8)( 9) .................... 4.8 Pts. (2.3L)
( 1) - Approximate quantity listed.
( 2) - Use an API energy conserving engine oil that is certified for
gasoline engines.
( 3) - Add this amount of fluid. Start engine and shift transmission
through all gears and back to Neutral. Add additional fluid to
bring fluid level to the MIN mark on dipstick. Recheck fluid
level with transmission at normal operating temperature. Adjust
fluid level to MAX mark on dipstick. Approximate drain and
refill capacity is 4.0 qts. (3.8L).
( 4) - Quantity may vary by type of oil cooler and oil cooler lines.
( 5) - Use only Mopar power steering fluid. DO NOT use automatic
transmission fluid.
( 6) - Rear differential may be identified by full-floating axles
shafts.
( 7) - Models with Trac-Lok limited slip differential must have 6 ozs.
(.18L) of Mopar Trac-Lok Friction Modifier added if lubricant is\
changed.
( 8) - Rear differential may be identified by number of bolts on rear
cover. The 8 1/4" ring gear has 10 bolts on rear cover and 9
1/4" ring gear has 12 bolts on rear cover.
( 9) - Models with Trac-Lok limited slip differential must have 5 ozs.
(.15L) of Mopar Trac-Lok Friction Modifier added if lubricant is\
changed.









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QUICK-SERVICE
SERVICE INTERVALS & SPECIFICATIONS
REPLACEMENT INTERVALS (CARAVAN, TOWN & COUNTRY, & VOYAGER) ( 1)








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Component Months Miles
Air Filter
Normal Service ..................... 24 ................. 30,000
Severe Service .................... ( 2) ............. ( 3) 15,000
Camshaft Timing Belt
2.4L
Normal Service .................... 96 ................ 120,000
Severe Service ................... ( 2) ................ 120,000
3.0L
Normal Service ( 4) ................ 48 ................. 60,000


E - T H EO RY/O PER ATIO N - D IE SEL

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Theory & Operation - Trucks - Diesel
Ram Pickup
INTRODUCTION
This article covers basic description and operation of engine
performance-related systems and components. Read this article before
diagnosing vehicles or systems with which you are not completely
familiar.
AIR INDUCTION SYSTEM
INTERCOOLER
NOTE: Intercooler may also be referred to as a charge air cooler.
Intercooler is a heat exchanger used to reduce intake air
temperature from turbocharger. Cooling of intake air results in an
increased air density for producing greater power and efficiency.
Intercooler is located in front of radiator. See Fig. 1.
Fig. 1: Exploded View Of Intercooler Assembly
Courtesy of Chrysler Corp.
TURBOCHARGER


E - T H EO RY/O PER ATIO N - R W D - G ASO LIN E

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Theory & Operation - Trucks & RWD Vans - Gasoline
Dakota, Durango, Ram Pickup, Ram Van, Ram Wagon
INTRODUCTION
This article covers the basic description and operation of
engine performance related systems and components. Read this article
before working on unfamiliar systems.
COMPUTERIZED ENGINE CONTROLS
POWERTRAIN CONTROL MODULE (PCM)
The PCM is a digital computer that controls ignition timing,
air/fuel ratio, fuel injector pulse width, ignition coil(s), spark
advance, emission control devices, cooling fan, charging system, idle
speed, cruise control (if equipped), fuel pump and tachometer. For PCM\
location, see PCM LOCATION. PCM uses data from various input sources
to control output devices in order to achieve optimum engine
performance for all operating conditions.
PCM has voltage converters that convert battery voltage to
regulated 5-volt output. The 5-volt output powers battery temperature
sensor, Camshaft Position (CMP) sensor on models equipped with
Distributorless Ignition System (DIS) or distributor on models without\
DIS, Crankshaft Position (CKP) sensor, Engine Coolant Temperature
(ECT) sensor, Intake Air Temperature (IAT) sensor, logic circuits,
Manifold Absolute Pressure (MAP) sensor, Throttle Position (TP) sens\
or
and Vehicle Speed Sensor (VSS) on some models.
PCM LOCATION









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Application Location
Dakota & Durango ................. Right Front Fender, Near Firewall
Ram Pickup, Ram Van & Ram Wagon .... On Firewall, Near Wiper Motor









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NOTE: Components are grouped into 2 categories. The first category,
INPUT DEVICES, includes components that control or produce
voltage signals monitored by the PCM. The second category,
OUTPUT SIGNALS, includes components controlled by the PCM
(this is accomplished by the PCM grounding individual
circuits).
INPUT DEVICES
Vehicles are equipped with different combinations of input
devices. Not all devices are used on all models. To determine
component location and input usage on a specific model, see
appropriate wiring diagram in WIRING DIAGRAMS article. Available input
signals include:
A/C Switch
Switch signals PCM that A/C has been selected. PCM then
activates A/C compressor clutch relay and maintains idle speed at a
preprogrammed RPM. This is done through control of Idle Air Control