1999 DODGE RAM water pump

HEATER HOSES
HIGH PRESSURE RELIEF VALVES (HPRV)
IDLERS
IN-LINE FILTERS
METAL FITTINGS
METAL LINES
MIX AND AIR CONTROL DOORS (BLEND DOORS)
O-RINGS
ORIFICE TUBES
PILOT-OPERATED ABSOLUTES (POAS)
PLENUMS
PRESSURE CONTROL VALVES
PRESSURE SENSORS
PULLEYS
RADIATORS
RECEIVER-DRIERS
REFRIGERANT
REFRIGERANT OIL
RELAYS
SEALS
SERVICE PORTS
SPRING LOCK COUPLINGS
SUCTION THROTTLING VALVES (STVS)
SWITCHES (ELECTRICAL)
TENSIONERS
THERMISTORS AND PRESSURE SENSORS
THERMOSTATS AND HOUSINGS
VACUUM HOSES AND TUBES
VACUUM RESERVOIRS
VACUUM TUBES
VALVES IN RECEIVER (VIRS)
WATER PUMPS (ELECTRIC AUXILIARY)
WIRING HARNESSES AND CONNECTORS
MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
(1) a Pledge of Assurance to their Customers and (2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards

Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket holes elongated,
affecting performance .. A .. Require repair or replacement.
Bracket holes elongated,
not affecting
performance ............ .. ........ No service suggested or
required.
Bracket loose, affecting
performance ............ A .. Require repair or replacement.
Bracket loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket missing ......... C ............ Require replacement.
Connection damaged ...... B .. Require repair or replacement.
Contaminated, affecting
performance ............ A ............ Require replacement.
Corroded internally ..... 1 ............ Suggest replacement.
Dessicant bag
deteriorated ........... A ........ (1) Require replacement.
Further inspection required.
Dessicant at the end of
its useful life
(saturated
with moisture) ......... 1 .. Suggest repair or replacement.
Filter screen torn ...... A .. Require replacement of screen.
Fitting damaged ......... B .. Require repair or replacement.
Fusible plug leaking .... A .... Require replacement of plug.
Inoperative ............. A ........... ( 2) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Pressure relief device
leaking ................ A . Require replacement of pressure
relief device.
Restricted .............. A .. Require repair or replacement.
Sight glass no longer
transparent ............ 2 ... Suggest replacement of drier.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Tubing connection
leaking ................ A .. Require repair or replacement.
( 1) - Inspect system to determine effects of dessicant bag
deterioration.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.









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WATER PUMPS (ELECTRIC AUXILIARY)
WATER PUMP (ELECTRIC AUXILIARY) 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.

VALVES. Connect 2 hoses with shutoff valves to manifold gauge set
center port. Connect one hose to vacuum pump and other hose to
refrigerant container. Weight of refrigerant container before and
after charging can be used to determine amount of refrigerant drawn
into system. Using vacuum pump, purge air from center hoses.
3) Fully open manifold gauge set low-side valve and
refrigerant container valve to allow refrigerant to enter A/C system.
When no more refrigerant is being drawn into A/C system, start engine
and allow to idle. Select MAX A/C, set blower motor speed to maximum
and allow remaining refrigerant to be drawn into A/C system.
NOTE: When ambient air temperature is high, it may be necessary to
use an external cooling fan to blow air through condenser and
radiator.
4) When proper amount of refrigerant has been added, close
refrigerant container valve. Allow any refrigerant remaining in hose
to be drawn into A/C system. When low-side pressure decreases to about
30 psi (2.1 kg/cm
), close center valve on manifold gauge set. Ensure
A/C system is operating properly. Disconnect manifold gauge set.
Install service port caps. Check system for leaks. See LEAK TESTING.
GENERAL MOTORS
Manufacturer recommends using A/C Refrigerant Recovery,
Recycling And Recharging (ACR4) System (J-39500). The ACR4 system ha\
s
one filtering cycle during recovery plus an automatic multiple pass
filtering during evacuation cycle. Follow manufacturer's instructions
provided with ACR4 equipment being used.
JEEP
Connect recovery/recycling equipment, meeting SAE standard
J1991 or J2210, to vehicle. Charge A/C system to specifications, using
equipment manufacturer's instructions.
LEAK TESTING
TYPES OF LEAK DETECTORS
Bubble Solution Detector
This is a solution applied externally at suspected leak
points. Leaking refrigerant will cause the detector to form bubbles
and foam. A soap and water solution also works well.
Dye Solution
This is a colored solution that may be introduced into the
A/C system. The dye will show up and color components at leak points.
Some manufacturers offer refrigerant containing a Red dye. This dye-
containing refrigerant is installed by normal charging procedures.
Other dye solutions are visible with a Black light only.
Electronic Leak Detector
This instrument will draw in any leaking refrigerant through
a test probe, and then sound an audible signal or create a flashing
light if refrigerant is found. It is the most sensitive of the leak
detectors used. Leak detectors are sensitive to windshield washing
solutions, many solvents and cleaners, and some adhesives. Ensure
surfaces near test areas are clean and dry to prevent false signal or
detector damage. Liquids ingested into detector will damage detector.
See Fig. 24 .

Fig. 6: Locating Intake Manifold Air Heater
Courtesy of Chrysler Corp.
NOTE: Restricted low-pressure fuel lines from fuel tank to fuel
transfer pump, fuel heater and fuel filter/water separator
may cause starting problems and prevent engine from
accelerating. Restricted high-pressure fuel lines from fuel
injection pump to fuel injector may cause starting problems,
poor engine performance and excessive Black smoke.
11) Check all fuel supply and returns lines for damage,
kinking or leakage. Check throttle linkage for binding. Check for a
stretched or disconnected throttle return spring.
12) Ensure all ground connections are tight and free of
corrosion. Ensure accessory drive belt is not damaged or slipping.
Check for loose or defective electrical connection on Crankshaft
Position (CKP) sensor. See Fig. 1.

13) On A/T models, ensure all electrical connectors are clean
and properly connected to electrical plugs on transmission case. On
all models, check for loose or defective electrical connections on
starter and starter solenoid.
MECHANICAL INSPECTION
Compression
Manufacturer does not provide information for checking
compression.
FUEL SYSTEM
AIR IN FUEL SYSTEM
NOTE: Air in the fuel system may cause hard starting, rough
running, excessive smoke, poor engine performance, engine
misfire, poor fuel economy and fuel knock. Air may enter fuel
system whenever fuel supply lines, fuel filter/water
separator, fuel injection pump, fuel injectors or high
-pressure fuel lines are removed or disconnected.
1) Inspect all low-pressure fuel lines from fuel tank to fuel
transfer pump, fuel heater and fuel filter/water separator for signs
of leakage. Inspect all high-pressure fuel lines for signs of leakage.
See FUEL INJECTOR & HIGH-PRESSURE FUEL LINES under FUEL SYSTEM.
2) After repairing fuel leak, bleed air from fuel system. See
FUEL LINE BLEEDING under FUEL SYSTEM in REMOVAL, OVERHAUL &
INSTALLATION - TRUCKS - DIESEL article.
FUEL HEATER
1) Fuel heater is located in fuel filter/water separator. See
Fig. 1 . Fuel heater uses a fuel heater temperature sensor for
controlling operation of the fuel heater.
2) A defective fuel heater may cause excessive wax build-up
in the fuel filter/water separator during cold ambient temperatures.
Wax build-up may cause hard starting, prevent engine from
accelerating, low power, Blue smoke or White smoke. For testing of
fuel heater and fuel heater temperature sensor, see SYSTEM & COMPONENT
TESTING - TRUCKS - DIESEL article.
FUEL HEATER RELAY
Ensure fuel heater relay, located in power distribution
center is installed correctly and that terminals are not corroded. For
fuel heater relay testing, see SYSTEM & COMPONENT TESTING - TRUCKS -
DIESEL article.
FUEL FILTER/WATER SEPARATOR
NOTE: A blocked or restricted fuel filter/water separator may cause
starting problems, prevent engine from accelerating, low
power or White smoke. If an excessive amount of water
collects in filter/separator in a short period of time, it
may be necessary to drain and clean fuel tank.
1) When ignition switch is first turned to ON position,
WATER-IN-FUEL (WIF) warning light should come on for 2 seconds to
perform bulb and wiring circuit test and then go off. WATER-IN-FUEL
(WIF) warning light is located on instrument panel, just below the

tachometer.
2) If WATER-IN-FUEL (WIF) warning light stays on, water
should be drained from fuel filter/water separator. To drain water
from fuel filter/water separator, ensure engine is not running. Place
drain pan below drain tube at fuel filter/water separator. See Fig. 1.
3) Rotate handle on drain valve forward, toward front of
vehicle to OPEN position. Drain valve is located near top of fuel
filter/water separator. See Fig. 1.
4) Allow water to drain until clean flow of diesel fuel
exists. Rotate handle on drain valve back to CLOSE position.
FUEL TRANSFER PUMP
NOTE: A defective fuel transfer pump may cause low power, hard
starting and White smoke. Check fuel transfer pump output
pressure (cranking and starting), pressure drop and fuel
supply.
Fuel Transfer Pump Preliminary Inspection
1) Check for restricted or leaking fuel supply line to fuel
transfer pump or fuel return line located on driver's side of engine.
See Fig. 1 . Repair fuel supply line or fuel return line if restricted
or leaking.
2) Check for fuel leaking from fuel transfer pump. Replace
fuel transfer pump if fuel is leaking. Check fuel transfer pump output
pressure.
Fuel Transfer Pump Output Pressure
1) Clean area around filter fitting plugs, then remove plugs.
See Fig. 7 . Install Test Fittings (AVU1-2). Install Fuel Pressure Test
Gauge (6828) at inlet port. See Fig. 7. To prevent engine starting,
remove fuel injection pump relay, located in power distribution
center.
2) Turn ignition switch to START position. Inlet pressure
should be 5-7 psi. Install fuel injection pump relay. Start engine.
Inlet pressure should be 10 psi. Using a scan tool, clear FTC. FTC may
set when relay is removed. Check pressure drop.
Fig. 7: Checking Fuel Transfer Pump Output Pressure
Courtesy of Chrysler Corp.
Pressure Drop Test
Turn engine off. Move pressure gauge from inlet port to

Removal
Disconnect negative battery cable. Remove drive belts from
crankshaft pulley. Remove fan and shroud. Remove crankshaft pulley and
vibration damper. Pry oil seal from front cover.
Installation
1) Use Seal Installer (6635) for seal installation. Installe\
r
should fit with minimum interference. If installer does not fit, front
cover must be removed and installed properly.
2) Position small diameter of oil seal over seal installer.
Using vibration damper bolt, tighten seal installer to draw seal into
position. Remove vibration damper bolt and seal installer. To complete
installation, reverse removal procedure.
FRONT COVER
Removal
1) Disconnect battery. Drain coolant. Remove power steering
pump (if equipped). Remove water pump. See WATER PUMP.
2) Remove crankshaft pulley and vibration damper. Loosen oil
pan bolts. Remove oil pan-to-front cover bolts on each side of oil
pan. Remove bolts, front cover and gasket. DO not damage oil pan
gasket.
Installation
1) Ensure sealing surfaces are clean. Apply a 1/8" (3.17 mm)\
bead of RTV sealant to oil pan gasket. Install gasket, front cover and
bolts. DO NOT tighten bolts at this time.
2) Install front cover oil seal. See FRONT COVER OIL SEAL.
Tighten front cover, oil pan and then vibration damper bolts to
specification. See TORQUE SPECIFICATIONS table. To complete
installation, reverse removal procedure.
TIMING CHAIN
Inspection
1) Remove front cover. See FRONT COVER. Position ruler at
camshaft sprocket, near timing chain link, to check timing chain
stretch.
NOTE: When applying torque to camshaft sprocket bolt, DO NOT allow
crankshaft to move. It may be necessary to hold crankshaft.
2) Place torque wrench on camshaft sprocket bolt. Apply 30
ft. lbs. (41 N.m) torque with cylinder heads installed, or 15 ft. lbs.\
(20 N.m) with cylinder heads removed, on camshaft sprocket bolt in
direction of engine rotation. Note reading on ruler.
3) Apply same amount of torque in opposite direction and note
amount of timing chain movement on ruler. If movement exceeds 1/8" (3.
17 mm), replace timing chain.
Removal
Rotate crankshaft so timing marks are aligned. See Fig. 8.
Remove camshaft sprocket bolt, camshaft sprocket, timing chain and
crankshaft sprocket.
Installation
1) Install timing chain and sprockets. Ensure timing marks
are aligned. See Fig. 8. Install camshaft sprocket bolt and tighten to
specification. See TORQUE SPECIFICATIONS table.
2) Ensure camshaft end play is within specification. See
CAMSHAFT table under ENGINE SPECIFICATIONS. If end play is not within
specification, replace thrust plate located between camshaft sprocket

block joint. See Fig. 11.
Fig. 11: Installing Rear Crankshaft Oil Seal
Courtesy of Chrysler Corp.
WATER PUMP