1999 DODGE RAM No spark no start


F - B ASIC T E STIN G - R W D - G ASO LIN E

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Basic Diagnostic Procedures Trucks & RWD Vans
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
The following diagnostic steps will help prevent overlooking
a simple problem. This is also where to begin diagnosis for a no-start
condition.
The first step in diagnosing any driveability problem is
verifying the customer's complaint with a test drive under the
conditions the problem reportedly occurred.
Before entering self-diagnostics, perform a careful and
complete visual inspection. Most engine control problems result from
mechanical breakdowns, poor electrical connections or
damaged/misrouted vacuum hoses. Before condemning the computerized
system, perform each test listed in this article.
NOTE: Perform all voltage tests with a Digital Volt-Ohmmeter (DVOM)\
with a minimum 10-megohm input impedance, unless stated
otherwise in test procedure.
PRELIMINARY INSPECTION & ADJUSTMENTS
VISUAL INSPECTION
Visually inspect all electrical wiring, looking for chafed,
stretched, cut or pinched wiring. Ensure electrical connectors fit
tightly and are not corroded. Ensure vacuum hoses are properly routed
and are not pinched or cut. Inspect air induction system for possible
vacuum leaks.
MECHANICAL INSPECTION
Compression
Ensure battery is fully charged. Warm engine to normal
operating temperature. Disconnect wire at ignition coil to prevent
engine from starting. Check engine compression with all spark plugs
removed and throttle wide open.
Check engine mechanical condition with a compression gauge,
vacuum gauge, or an engine analyzer. See engine analyzer manual for
specific instructions.
COMPRESSION SPECIFICATIONS









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Application Specification
Compression Ratio
Ram Pickup (8.0L) .......................................... 8.4:1\
All Others ................................................. 9.1:1
Normal Compression Pressure .................................... ( 1)

and camshaft. To install remaining components, reverse removal
procedure.
Fig. 8: Aligning Timing Marks
Courtesy of Chrysler Corp.
ROCKER ARMS
Removal
Disconnect spark plug wires, PCV and fuel evaporation hoses.
Remove valve covers. Remove bolts, pivots, and rocker arms. Wire
components together for installation reference. Mark each push rod for
location, and remove (if necessary).
CAUTION: To avoid piston-to-valve contact during rocker arm
installation, crankshaft must be placed in specified
position. Wait 5 minutes before starting engine to allow
valve lifters to bleed down after rocker arm installation.
Installation
1) On 3.9L engine, locate "V6" mark stamped on vibration
damper (147 degrees ATDC). Rotate engine by hand until "V6" mark lines\
up with TDC mark on timing chain cover.
2) On 5.2L and 5.9L engines, locate "V8" mark stamped on
vibration damper (147 degrees ATDC). Rotate engine by hand until "V8"
mark lines up with TDC mark on timing chain cover.
3) Install rocker arm and pivot assemblies and tighten bolt
to 21 ft. lbs. (28 N.m). Wait 5 minutes before starting engine to
allow valve lifters to bleed down after rocker arm installation. To
install remaining components, reverse removal procedure. Tighten valve
cover bolts to 95 INCH lbs. (11 N.m).
VALVE LIFTERS

Engine Mount Through-Bolt
Dakota 2WD & Durango 2WD ................................. 50 (68)\
Dakota 4WD, Durango 4WD & Ram Pickup .................... 75 (102)\
Grand Cherokee ............................................. 60 (81)\
Engine Mount-To-Cylinder Block Bolt
Dakota & Durango ......................................... 30 (41)\
Ram Pickup ............................................... 60 (81)\
Ram Van/Wagon & Grand Cherokee ............................. 65 (88)\
Engine Mount-To-Frame Bracket Bolt/Nut
Ram Pickup & Ram Van/Wagon .............................. 75 (102)\
Exhaust Manifold Bolt & Nut
Durango .................................................. 18 (24)\
All Others ................................................. 25 (34)\
Flywheel/Flexplate-To-Crankshaft Bolt ...................... 55 (75)\
Front Cover Bolt ........................................... 30 (41)\
Heat Shield Bolts .......................................... 30 (41)\
Main Bearing Cap Bolt ..................................... 85 (115)\
Oil Drain Plug ............................................. 25 (34)\
Oil Filter Adapter Stud .................................... 50 (68)\
Oil Pan Bolt ............................................... 18 (24)\
Oil Pump Bolt .............................................. 30 (41)\
Rocker Arm Bolt ............................................ 21 (28)\
Shift Motor Bolt
Dakota 4WD & Durango 4WD ................................. 65 (88)\
Spark Plug ................................................. 30 (41)\
Starter Bolts .............................................. 50 (68)\
Throttle Body Bolt ......................................... 17 (23)\
Transfer Case Yoke Bolt
Dakota 4WD & Durango 4WD ................................. 20 (27)\
Vibration Damper Bolt .................................... 135 (183)\
Water Pump Bolt ............................................ 30 (41)\
INCH Lbs. (N.m)
Intake Manifold Bolt ( 4)
Step 1 .................................................. 24 (2.7)\
Step 2 .................................................. 48 (5.4)\
Step 3 .................................................. 84 (9.5)\
Step 4 (Verify Torque All Bolts) ........................ 84 (9.5\
)
Intake Manifold Plenum Pan Bolt
Step 1 .................................................. 24 (2.7)\
Step 2 .................................................. 48 (5.4)\
Step 3 .................................................. 84 (9.5)\
Step 4 (Verify Torque) .................................. 84 (9.5\
)
Oil Pump Cover Bolt ........................................ 97 (11)\
Valve Cover Bolts .......................................... 95 (11)\
( 1) - Bolts through clutch housing into cylinder block.
( 2) - Bolts through cylinder block into clutch housing.
( 3) - Tighten bolts in sequence. See 7.
( 4) - Tighten bolts in sequence. See 5 and 6.









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ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS (3.9L)








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Application Specification
Displacement .................................... 239 Cu. In. (3.9L)\
Bore ............................................... 3.91" (99.3 mm)\
Stroke ............................................. 3.31" (84.1 mm)\

CLUTCH PEDAL POSITION SWITCHES
COLD START INJECTORS
CONNECTORS
COOLANT
COOLANT RECOVERY TANKS
COOLING FAN MOTOR MODULES
COOLING FAN MOTOR RELAYS AND MODULES
COOLING FAN MOTOR RESISTORS
COOLING FAN MOTOR SENSORS AND SWITCHES
COOLING FAN MOTOR SWITCHES
COOLING FAN MOTORS
CRANKSHAFT POSITION SENSORS
DECEL VALVES
DEFLECTORS
DIP STICKS AND TUBES
DIP STICK TUBES
DISTRIBUTOR ADVANCES AND RETARDERS (MECHANICAL AND VACUUM)
DISTRIBUTOR BOOTS AND SHIELDS
DISTRIBUTOR CAPS
DISTRIBUTOR RETARDERS (MECHANICAL AND VACUUM)
DISTRIBUTOR ROTORS
DISTRIBUTOR SHIELDS
DISTRIBUTORS
EARLY FUEL EVAPORATION VALVES (HEAT RISER ASSEMBLIES)
EGR COOLERS
EGR EXHAUST MANIFOLD PASSAGES
EGR INTAKE AND EXHAUST MANIFOLD PASSAGES
EGR PLATES AND COOLERS
ELECTRONIC SPARK CONTROL MODULES
ELECTRONIC TRANSMISSION CONTROL DEVICES
ELECTRONIC TRANSMISSION FEEDBACK DEVICES
ENGINE COOLANT TEMPERATURE SENSORS
ENGINE COOLING SYSTEMS
ENGINE COVERS (OIL PAN, VALVE COVER, TIMING COVER)
ENGINE OIL
ENGINE OIL CANISTERS
ENGINE OIL COOLERS (EXTERNAL)
ENGINE OIL DRAIN PLUGS AND GASKETS
ENGINE OIL FILTERS AND CANISTERS
ENGINE OIL GASKETS
ENGINE OIL PRESSURE GAUGES (MECHANICAL)
EVAPORATIVE EMISSION (EVAP) CANISTER FILTERS
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE DEVICES
EVAPORATIVE EMISSION (EVAP) CANISTERS
EVAPORATIVE EMISSION (EVAP) FEEDBACK DEVICES
EXHAUST GAS RECIRCULATION DEVICES
EXHAUST GAS RECIRCULATION FEEDBACK DEVICES
EXPANSION PLUGS
FAN CONTROL SENSORS
FUEL
FUEL ACCUMULATORS AND DAMPERS
FUEL AND COLD START INJECTORS
FUEL DAMPERS
FUEL DELIVERY CHECK VALVES
FUEL DISTRIBUTORS (BOSCH CIS)
FUEL FILLER NECKS AND RESTRICTORS
FUEL FILTERS
FUEL INJECTORS
FUEL LEVEL SENDERS7
FUEL PRESSURE REGULATORS
FUEL PUMPS (IN-TANK AND EXTERNAL, ELECTRICAL OR MECHANICAL)
FUEL RAILS
FUEL RESTRICTORS

pulley for the accessory drive belt, as these bolts are under
tension. If necessary to remove these bolts, accessory drive
belt must be removed first.
2) Remove ignition coil retaining bolts or nuts with ignition
coil from the ignition coil mounting bracket. On 3.9L, 5.2L and 5.9L
with light-duty emissions, DO NOT remove ignition coil-to-cylinder
head mounting bracket bolts, as these bolts are under tension. On all
applications, to install, reverse removal procedure. Tighten ignition
coil retaining bolts or nuts to specification. See TORQUE
SPECIFICATIONS.
Removal & Installation (Ram Pickup 8.0L)
1) Two separate ignition coils are located above passenger's
side valve cover. Each ignition coil can be serviced separately. On
all ignition coil applications, disconnect spark plug wires and
electrical connector from ignition coil.
2) Remove ignition coil retaining bolts and ignition coil
from ignition coil mounting bracket. To install, reverse removal
procedure. Ensure ignition coil is mounted on ignition coil mounting
bracket with electrical connector facing downward. Tighten ignition
coil retaining bolts to specification. See TORQUE SPECIFICATIONS.
FUEL SYSTEM
FUEL SYSTEM PRESSURE RELEASE
WARNING: Always release fuel pressure before disconnecting any fuel
injection-related component. DO NOT allow fuel to contact
engine or electrical components.
1) Remove fuel cap from fuel tank. Note location of spring
loaded flapper valve inside fuel tank filler tube assembly. Flapper
valve is located just below the fuel cap area on fuel tank filler tube
assembly. Flapper valve is used as a secondary way of sealing the fuel
tank if fuel cap was not properly tightened.
WARNING: When opening flapper valve inside fuel tank filler tube
assembly, ensure a non-metallic object is used to prevent any
sparks.
2) Using a non-metallic object, push flapper valve inside
filler tube assembly downward to release any pressure from the fuel
tank. Ensure all pressure is released from fuel tank.
3) Remove fuel pump relay from Power Distribution Center
(PDC). Fuel pump relay may be identified by label on inside of PDC
cover. See POWER DISTRIBUTION CENTER (PDC) LOCATION table.
4) On all models, start engine and allow engine to idle until
engine stalls. Attempt to restart engine until engine will no longer
run. Turn ignition off.
CAUTION: Ensure steps 1) through 4) are performed before proceeding.
Steps 3) and 4) must be performed to ensure most of the fuel
pressure is released from fuel rails to prevent an excessive
amount of fuel being delivered into the cylinders.
5) Remaining fuel pressure is released by energizing a fuel
injector. Disconnect electrical connector at any fuel injector.
6) Connect jumper wire between one electrical terminal on
fuel injector and positive battery terminal. Connect another jumper
wire on remaining electrical terminal on fuel injector.

Ram Pickup, Ram Van & Ram Wagon ........... (2) .............. ( 2)
Town & Country
3.3L & 3.8L ............................. ( 2) .............. ( 2)
Voyager
2.4L
A/C & Generator ...................... 190 (86) ...... 115 (52\
)
Power Steering ....................... 140 (64) ....... 90 (41\
)
3.0L
A/C .................................. 150 (68) ....... 80 (36\
)
Generator & Power Steering ............. ( 2) .............. ( 2)
3.3L .................................... ( 2) .............. ( 2)
( 1) - Used belt is a belt that has been in service for more than 15
minutes.
( 2) - Automatic belt tensioner is used. Belt tension adjustment is not
required.









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MECHANICAL CHECKS
ENGINE COMPRESSION
Ensure battery is fully charged. Warm engine to normal
operating temperature. Disconnect wire at ignition coil to prevent
engine from starting. Check engine compression with all spark plugs
removed and throttle wide open.
COMPRESSION SPECIFICATIONS









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Application Specification
Compression Ratio
Caravan
2.4L ...................................................... 9.4:1
3.0L ...................................................... 8.9:1
3.3L ...................................................... 8.9:1
3.8L ...................................................... 9.6:1
Dakota & Durango ........................................... 9.1:1
Ram Pickup
3.9L, 5.2L & 5.9L (Gasoline) .............................. 9.1:1\
5.9L (Diesel) ............................................ 17.5:1\
8.0L ...................................................... 8.4:1
Ram Van & Ram Wagon ........................................ 9.1:1
Town & Country
3.3L ...................................................... 8.9:1
3.8L ...................................................... 9.6:1
Voyager
2.4L ...................................................... 9.4:1
3.0L ...................................................... 8.9:1
3.3L ...................................................... 8.9:1
Normal Compression Pressure
Caravan
2.4L ............................. 170-225 psi (11.9-15.7 kg/cm
)
3.0L ...................................... 178 psi (12.5 kg/cm)
3.3L & 3.8L ................................................. ( 1)
Dakota
2.5L .............................. 120-150 psi (8.4-10.5 kg/cm
)
3.9L, 5.2L & 5.9L ........................................... ( 1)
Durango ...................................................... ( 1)
Ram Pickup, Ram Van & Ram Wagon .............................. ( 1)
Town & Country ............................................... ( 1)
Voyager

drive plate. PCM uses this information to determine fuel injection
sequence, ignition signal and spark timing.
Cruise Control Switch
Cruise control switch provides PCM with 3 separate inputs.
ON/OFF switch input informs PCM that cruise control system has been
activated. SET/COAST switch input informs PCM that set vehicle speed
has been selected, or if depressed will decelerate until switch is
released. RESUME/ACCEL switch input informs PCM that a previously set
speed has been selected or, if depressed, will increase speed until
released. PCM uses these inputs to control cruise control servo.
Engine Coolant Temperature (ECT) Sensor
ECT sensor monitors engine coolant temperature. PCM uses ECT
sensor information to adjust air/fuel mixture and idle speed and to
control radiator cooling fans as necessary.
Fuel Level Sensor
PCM supplies a 5-volt reference signal to fuel module in gas
tank. Fuel level sensor sends a signal to PCM indicating fuel level.
PCM monitors this signal to prevent a false misfire signal if fuel
level is less than 15 percent. PCM also sends this signal to fuel
gauge.
Heated Oxygen Sensor (HO2S)
HO2S produces a small electrical voltage (0-1 volt) when
exposed to heated exhaust gas. HO2S is electrically heated for faster
warm-up. Heating element is powered through Auto Shutdown (ASD) relay.\
HO2S acts like a rich/lean (air/fuel ratio) switch by
monitoring oxygen content in exhaust gas. This information is used by
PCM to adjust air/fuel ratio by adjusting injector pulse width.
HO2S produces low voltage when oxygen content in exhaust gas
is high. When oxygen content in exhaust gas is low, HO2S produces a
higher voltage.
Ignition Switch
Ignition switch sends signal to PCM indicating whether switch
is on, off or cranking (ST). When PCM receives ON signal, it energizes\
ASD relay coil and supplies power to sensors and actuators. When PCM
receives ST signal, it controls fuel injection rate, idle speed,
ignition timing, etc. for optimum cranking conditions.
Intake Air Temperature (IAT) Sensor
IAT sensor measures temperature of incoming intake air. This
information is used by PCM to adjust air/fuel mixture.
Manifold Absolute Pressure (MAP) Sensor
MAP sensor monitors intake manifold vacuum. Sensor transmits
information on manifold vacuum and barometric pressure to PCM. MAP
sensor information is used with information from other sensors to
adjust air/fuel mixture.
Oil Pressure Sensor
Sensor sends a signal to PCM to indicate oil pressure.
Park/Neutral (P/N) Switch (A/T Models)
This switch may also be referred to as a Park/Neutral
Position (PNP) switch. P/N switch is available on vehicles equipped
with A/T only. Switch prevents engine starter from engaging if vehicle
is in any gear except Park or Neutral.
P/N switch input (varied with gear selection) is used to
determine idle speed, fuel injector pulse and ignition timing.

PCM also operates A/C compressor clutch (if A/C is requested)\
through A/C clutch relay. When engine reaches operating temperature,
vehicle will go into idle mode and PCM will begin monitoring HO2S
input and go into closed loop operation.
* Idle - When engine is at operating temperature, this is a
closed loop mode. In idle mode, PCM now adds HO2S signal to
array of inputs used in ENGINE WARM-UP mode. PCM maintains
correct air/fuel ratio by adjusting injector pulse width and
ignition timing. PCM also controls A/C clutch operation (if
A/C is requested).
* Cruise - When engine is at operating temperature, this is a
closed loop mode. Using information from A/C switch, battery
voltage, CKP sensor, ECT sensor, IAT sensor, MAP sensor and
CMP sensor. PCM also monitors A/C request and P/N switch (A/T
only), TP sensor and VSS signals for fuel calculation. PCM
monitors HO2S and adjusts air/fuel ratio as needed. PCM
controls engine idle speed through IAC motor. PCM controls
spark advance as necessary.
* Acceleration - This is an open loop mode. When PCM
recognizes an abrupt increase in throttle position or
manifold pressure as a demand for increased engine output, it
increases injector pulse width in response to increased fuel
demand. HO2S signals are ignored.
* Deceleration - This is an open loop mode when engine is at
operating temperature and under deceleration. When PCM
receives inputs signaling a closed throttle and an abrupt
decrease in manifold pressure, it reduces injector pulse
width to lean air/fuel mixture. Under certain RPM and closed
throttle position conditions, HO2S signals are ignored and
PCM cuts off fuel injection until idle speed is reached. PCM
also drives IAC motor for smooth transition to idle mode.
* Wide Open Throttle - This is an open loop mode. When PCM
senses wide open throttle, it grounds fuel injectors in
sequence, it ignores HO2S input and it controls pulse width
to supply a pre-determined amount of additional fuel. PCM
also adjusts spark advance and disengages A/C clutch for
approximately 15 seconds.
* Ignition Switch Off - This is an open loop mode. PCM drives
IAC motor into position in anticipation of next start-up. All
outputs are turned off, no inputs are monitored and PCM shuts
down.
Sequential Fuel Injection (SFI)
Individual, electrically pulsed injectors (one per cylinder)
are located in intake manifold runners. These injectors are next to
intake valves in intake manifold. PCM controls injection timing based
on crankshaft position signal input. PCM regulates air/fuel mixture by
length of time injector stays open (pulse width) based on inputs from
HO2S, ECT sensor, MAP and other sensors.
IDLE SPEED
NOTE: DO NOT attempt to correct a high idle speed condition by
turning factory sealed throttle body throttle plate set
screw. This will not change idle speed of warm engine, but
may cause cold start problems due to restricted airflow.
Idle Air Control (IAC) Motor
IAC motor adjusts idle speed to compensate for engine load
and ambient temperature by adjusting amount of air flowing through by-
pass in back of throttle body. PCM uses ECT sensor, VSS, TP sensor and