Engine System Testing & Engine Component Testing - 5.9l Dodge Ram Wagon B1500

INTRODUCTION

Before testing individual components or systems, perform BASIC DIAGNOSTIC PROCEDURES procedures in BASIC TESTING - 5.9L article. Since many computer controlled and monitored components set a fault message if they malfunction, also perform procedures in the TESTS W/CODES - 5.9L article.

Note. Testing of individual components does not isolate possible shorts or opens in wiring harness of electronically controlled systems. Perform all voltage tests using a Digital Volt-Ohmmeter (DVOM) with a minimum 10-megohm input impedance unless otherwise instructed in procedure. Use an ohmmeter to isolate wiring harness shorts or opens.

POWERTRAIN CONTROL MODULE (PCM)

The PCM is located between driver's side front fender and power distribution center, near battery. The PCM power and ground circuits may be checked by performing specified No Trouble Code (NTC) test. See TEST NTC-11A CHECKING PCM POWER & GROUND CIRCUITS in the TESTS W/CODES - 5.9L article.

SENSORS

Note. In the following test, an analog type voltmeter must be used. Use a small piece of wire (paperclip) to access distributor connector terminals while connector is plugged in.

Camshaft Position (CMP) Sensor

1. DO NOT disconnect distributor connector. Using an analog voltmeter, connect positive voltmeter lead to CMP sensor signal circuit (Tan/Yellow) at distributor wiring harness connector. Connect negative voltmeter lead to ground circuit (Black/Light Blue wire) at distributor wiring harness connector. Set voltmeter to 15-volt DC scale.
2. With distributor cap removed, manually rotate crankshaft until pulse ring enters sync signal generator on CMP sensor. Distributor rotor should point toward rear of engine. Turn ignition on. If voltage is about 5 volts, go to step 8). If voltage is not about 5 volts, check voltmeter leads for good connections.
3. Repair connections as necessary and repeat step 2). If connections are okay and voltage is still not about 5 volts, check voltage at supply circuit (Violet/White wire) at CMP sensor harness connector. If voltage is present, replace CMP sensor. If voltage is not present, go to next step.
4. Backprobe PCM connector and measure voltage between terminal A17 (Violet/White) and ground. PCM is located on right side of engine compartment. If no voltage is present, see appropriate CMP sensor circuit test in the «TESTS W/CODES - 5.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l) article. If voltage is present, go to next step.
5. Check continuity of supply circuit (Violet/White wire) between distributor connector and PCM. If no continuity exists, repair wiring harness as necessary. If continuity exists, go to next step.
6. Check continuity of CMP sensor signal wire (Tan/Yellow wire) between distributor connector and terminal A18 at PCM connector. If no continuity exists, repair wiring harness as necessary. If continuity exists, go to next step.
7. Check continuity between ground and ground circuit (Black/Light Blue wire) at distributor connector. If no continuity exists, repair wiring harness as necessary. If continuity exists, go to next step.
8. Observe voltmeter and crank engine. Voltmeter needle should fluctuate from 0-5 volts. If voltage is as specified, CMP sensor is operating properly and sync pulse signal is being generated. If voltage is not as specified, replace CMP sensor.

Crankshaft Position (CKP) Sensor

Disconnect CKP sensor connector. CKP sensor is bolted to top of cylinder block, near rear of right cylinder head. Measure resistance between terminals "B" and "C" at CKP sensor connector. (Scheme 150) Replace sensor if any resistance exists

Scheme 150

Engine Coolant Temperature (ECT) Sensor

ECT sensor is mounted in intake manifold between generator and A/C compressor. Turn ignition off. Disconnect ECT sensor connector. Using an ohmmeter, measure resistance between sensor terminals. If resistance is not as specified, replace sensor. See ECT SENSOR & IAT SENSOR RESISTANCE table.

ECT SENSOR & IAT SENSOR RESISTANCE

Heated Oxygen Sensor (HO2S)

To test heating element, disconnect HO2S connector. Measure resistance between 2 White wire terminals at sensor connector. If resistance is not 5-7 ohms, replace sensor. To test sensing circuit, see the TESTS W/CODES - 5.9L article.

Intake Air Temperature (IAT) Sensor

IAT sensor is mounted in intake manifold extending into air stream. Sensor is located at right front of manifold under throttle cable bracket. Turn ignition off. Disconnect IAT sensor connector. Using ohmmeter, measure resistance between sensor terminals. If resistance is not as specified, replace sensor. See resistance specifications in the ECT SENSOR & IAT SENSOR RESISTANCE table.

Manifold Absolute Pressure (MAP) Sensor

1. MAP sensor is connected to throttle body by a rubber fitting. Inspect rubber connection from MAP sensor-to-throttle body. Repair as necessary. NOTE: MAP sensor test must be performed with wiring connector connected.
2. Measure MAP sensor voltage between Black/Light Blue wire (ground) and Dark Green/Red wire (signal circuit) at MAP sensor connector. With ignition on and engine off, output voltage should be 4-5 volts. With engine running, at idle and engine at normal operating temperature, sensor output voltage should be 1.5-2.1 volts. If voltage is not as specified, go to next step.
3. Check wiring between MAP sensor connector and PCM connector for shorts or open circuits. Repair wiring as necessary. If wiring is okay, replace MAP sensor.

Throttle Position (TP) Sensor

1. TP sensor is located on throttle body. Disconnect and inspect TP sensor connector. Repair as necessary. Turn ignition on, with engine off. Measure voltage between ground and Orange/Dark Blue wire at TP sensor connector.
2. Voltage should be more than 200 millivolts (0.2 volt) at idle. At Wide Open Throttle (WOT), voltage should be less than 4.8 volts. Voltage should increase gradually as throttle is increased from idle to WOT.
3. If voltage readings are not as specified, check wiring between TP sensor and PCM connector for shorts or open circuits. Repair wiring as necessary. If wiring is okay, replace TP sensor.

Vehicle Speed Sensor (VSS)

VSS is located on transmission extension housing on 2WD models. VSS is located on transfer case on 4WD models. For VSS testing, see the TESTS W/CODES - 5.9L article.

Park/Neutral Position Switch

1. Park/neutral position switch is located on transmission. Turn ignition off. Put shift selector in Park position. Disconnect switch harness connector. Using ohmmeter, check continuity between switch center terminal and transmission case.
2. Continuity should exist in Park and Neutral positions only. If continuity exists, switch is functioning properly. If continuity does not exist, replace switch.

A/C Clutch Relay, Auto Shutdown (ASD) Relay & Fuel Pump Relay

1. Relays are located in power distribution box in engine compartment. Relay terminal numbers are stamped on bottom of relay. Remove relay. If any of the following resistance and continuity tests fail, replace relay.
2. Using an ohmmeter, measure resistance between terminals No. 85 and 86. Resistance should be 70-80 ohms.
3. Connect ohmmeter between terminals No. 87A and 30. Continuity should exist. Connect ohmmeter between terminals No. 87 and 30. Continuity should not exist.
4. Using a pair of jumper wires, connect a jumper wire between terminal No. 85 and battery ground. Connect other jumper wire to battery positive terminal, but DO NOT connect to relay yet. CAUTION: DO NOT allow ohmmeter to contact terminal No. 85 or 86 during following test. Damage to ohmmeter may result.
5. Attach other jumper wire to relay terminal No. 86 to activate relay. Continuity should exist between terminals No. 87 and 30, but not between terminals No. 87A and 30. Disconnect jumper wires from battery and relay.

FUEL DELIVERY

Note. For fuel system pressure testing, see the BASIC TESTING - 5.9L article.

Fuel Injector

Disconnect fuel injector connector. Using ohmmeter, measure resistance between injector terminals. If resistance is not 13.3-15.7 ohms, replace fuel injector.

IDLE AIR CONTROL (IAC) MOTOR

See the TESTS W/CODES - 5.9L article.

IGNITION SYSTEM

Note. For basic ignition checks, see BASIC TESTING - 5.9L article.

EMISSION SYSTEMS & SUB-SYSTEMS

Note. To locate emission components, refer to emission control information label in engine compartment.

EXHAUST GAS RECIRCULATION (EGR)

Note. To ensure proper EGR system operation, all passages and moving parts must be free from restrictive deposits. Clean or replace components as necessary.

EGR System Operation Check

1. Warm engine to operating temperature. Check condition of all EGR system tubes, hoses and electrical connections.
2. Start engine. Snap throttle to 2000-2800 RPM and check for EGR valve stem movement. If EGR stem moves, proceed to EGR GAS FLOW TEST. If no stem movement occurs, see the «TESTS W/CODES - 5.9L»(/dodge/ram-wagon-b1500/1996-1997/remont/testing-diagnostics/#engine-controls-tests-wcodes-59l) article for further testing procedures.

EGR Gas Flow Test

1. Warm engine to operating temperature. Disconnect vacuum hose from diaphragm (upper nipple) on EGR valve and attach a hand-held vacuum pump. With engine running, slowly apply 5 in Hg. to EGR valve. EGR valve stem should move, and engine should stumble or stall.
2. If EGR valve stem moved but idle speed remained steady, EGR valve, EGR tube, intake manifold or exhaust manifold may be plugged with carbon. Remove and clean/replace necessary components.
3. If EGR valve stem did not move, reapply vacuum to diaphragm and observe vacuum gauge on vacuum pump. If vacuum leaks down, diaphragm is ruptured and EGR valve must be replaced. If vacuum holds and stem does not move, carefully attempt to clean valve. If cleaning does not free stem, replace EGR valve.

EVAP Canister

EVAP canister is located in engine compartment. Canister has no moving parts. Check for loose, missing, cracked or broken connections and parts. Repair or replace as necessary. No liquid should be in canister.

PCV Valve

1. With engine running at curb idle, remove PCV valve from grommet. If valve is functioning properly, a hissing sound will be heard as air passes through valve.
2. With engine running, place finger over valve inlet. Strong vacuum should be felt at valve inlet. Stop engine. Remove and shake PCV valve to ensure a metallic clicking noise can be heard, indicating valve is free. Reinstall PCV valve.
3. Remove crankcase ventilation filter or oil filler cap from valve cover. Hold a piece of stiff paper over opening. After allowing about one minute for crankcase pressure stabilization, paper should be drawn against opening.
4. If paper is held against opening, performance is okay. If paper is not held against opening, replace PCV valve and retest. If performance does not improve, inspect system for restrictions and clean as necessary.

MISCELLANEOUS CONTROLS

Note. Although some controlled devices listed here are not technically engine performance components, they can affect driveability if they malfunction.

A/C CLUTCH RELAY

A/C Clutch Relay

See RELAYS .

See also:
• BASIC TESTING - 5.9L
• TESTS W/CODES - 5.9L
• ECT SENSOR & IAT SENSOR RESISTANCE