sensor DODGE RAM 1999 Service Repair Manual

FUEL LINE BLEEDING
NOTE: Fuel line bleeding is necessary if fuel injection pump is
replaced, fuel filter/water separator is not filled with
diesel fuel before installing or vehicle ran out off fuel.
Bleed high-pressure fuel lines if connections are loosened or
replaced. If engine has not been operated for an extended
time, bleed fuel lines before next initial engine start-up.
WARNING: DO NOT bleed fuel lines on a hot engine, as high exhaust
temperatures may cause a fire. Carefully bleed fuel lines, as
fuel is under extremely high pressure and could penetrate
skin. Use safety goggles and protective clothing when
bleeding fuel lines.
1) Loosen banjo bolt holding low-pressure fuel supply line to
side of fuel injection pump. Wrap a towel around banjo fitting to
catch fuel. Crank engine quickly and release key before engine starts.
This will operate fuel transfer pump for about 25 seconds.
2) If fuel is not present at fuel supply line after 25
seconds, turn ignition off. Repeat engine crank procedure until fuel
is present at fuel supply line. Tighten banjo bolt at fuel supply line
to specification. See TORQUE SPECIFICATIONS.
CAUTION: Ensure parking brake is applied and transmission is in
Neutral before bleeding fuel injection pump or high-pressure
fuel lines. DO NOT operate starter for more than 30 seconds
when bleeding fuel injection pump or high-pressure fuel
lines. Allow 2-minute intervals between starter operations.
3) To bleed air from fuel injection pump, ensure parking
brake is applied and transmission is in Neutral, as engine may start
when operating starter to bleed air from fuel injection pump. Operate
starter for 30 seconds to bleed any trapped air in fuel injection
pump.
4) To bleed high-pressure fuel lines, ensure parking brake is
applied and transmission is in Neutral, as engine may start when
operating starter to bleed high-pressure fuel lines. Loosen high-
pressure fuel line nut at fuel injector.
5) Operate starter until steady fuel flow exists at high-
pressure fuel line. Tighten high-pressure fuel line nut to
specification. See TORQUE SPECIFICATIONS. Start engine. Repeat
procedure on each high-pressure fuel line until engine operates
smoothly.
FUEL FILTER/WATER SEPARATOR & WATER-IN-FUEL SENSOR
NOTE: Vehicle also contains an in-tank fuel filter located on
bottom of fuel tank module. For servicing procedure, see FUEL
TANK MODULE & IN-TANK FUEL FILTER under FUEL SYSTEM.
NOTE: When fuel filter/water separator is being replaced,
manufacturer recommends cleaning the pre-filter. See FUEL
HEATER under FUEL SYSTEM for servicing of pre-filter.
Removal
1) Ensure engine is off. Place drain pan below drain tube at
fuel filter/water separator. See Fig. 3. Rotate handle on drain valve
forward, toward front of vehicle to DRAIN position. Drain valve is
located near top of fuel filter/water separator. See Fig. 3. Once fuel
is drained from fuel filter/water separator, rotate handle on drain
valve back to CLOSE position.

2) Disconnect drain tube from drain valve. Disconnect
electrical connector for Water-In-Fuel (WIF) sensor at bottom of fuel
filter/water separator. See Fig. 3.
3) Support canister for fuel filter/water separator and
remove canister nut from top of filter mounting head. See Fig. 3.
Remove canister with fuel filter/water separator and seal ring from
filter mounting head. Remove fuel filter/water separator from
canister.
4) Remove "O" ring from top of shaft inside the canister.
Remove bolts and drain valve from canister (if necessary).
5) Check the 2 probes inside the canister on end of WIF
sensor for contamination. Clean probes if contaminated. If
contamination cannot be removed from the probes, replace WIF sensor.
If replacing WIF sensor, remove WIF sensor and "O" ring from canister.
6) Fuel heater is located inside fuel filter housing. Heater
mounting plate, heating element, temperature sensor, and wiring
harness are serviced as an assembly. Disconnect heater electrical
connector from engine wiring harness near upper rear part of filter.
7) Disconnect electrical connector at end of 2-wire harness
before attempting to pass harness through filter header. Remove clip
retaining wires to connector. Remove wires from connector. Remove 3
fuel heater screws. Press on heater sealing grommet to remove heater
from filter canister header. Pass wire through hole in filter header.
Remove fuel heater.
Installation
1) Ensure inside of canister is clean. Using NEW "O" ring,
install WIF sensor on canister (if removed). Tighten WIF sensor to
specification. See TORQUE SPECIFICATIONS.
2) Install drain valve on canister (if removed). Tighten
drain valve-to-canister bolts to specification. See TORQUE
SPECIFICATIONS.
3) Install NEW "O" ring on shaft inside canister. Coat "O"
ring with diesel fuel. Install NEW fuel filter/water separator and NEW
seal ring in canister. Coat seal ring with diesel fuel.
NOTE: Canister for fuel filter/water separator should be filled
with diesel fuel before installing. If canister cannot be
filled with diesel fuel, low-pressure fuel lines must be bled
after installation.
CAUTION: When installing canister on filter mounting head, ensure tab
areas on outside of canister align with tabs on filter
mounting head. This must be done to prevent damage to
canister and filter mounting head.
4) Fill canister for fuel filter/water separator with diesel
fuel. Install canister with fuel filter/water separator on filter
mounting head. Ensure canister fully engages with filter mounting head
and tab areas on outside of canister align with tabs on filter
mounting head.
5) Install and tighten canister nut to specification. See
TORQUE SPECIFICATIONS.
6) To install remaining components, reverse removal
procedure. If canister was not filled with diesel fuel, bleed low-
pressure fuel lines before starting engine. See FUEL LINE BLEEDING
under FUEL SYSTEM. Start engine and check for fuel leaks.
FUEL TANK MODULE & IN-TANK FUEL FILTER
NOTE: In-tank fuel filter is located on bottom of fuel tank module
which also contains the fuel gauge sending unit. Fuel tank
module is mounted on top of fuel tank.

Removal
1) Remove nameplate located above rocker lever covers. Remove
fuel injector drain line-to-fuel injector banjo bolt and seal washer
from each fuel injector. Plug all fuel openings.
2) Remove fuel injector drain line assembly retaining clamp
at rear of intake manifold. Remove fuel injector drain line bolt with
seal washers at filter mounting head. See Fig. 3. Remove fuel injector
drain line assembly.
Installation
To install, reverse removal procedure using NEW seal washers.
Tighten bolts to specification. See TORQUE SPECIFICATIONS.
FUEL HEATER
Removal & Installation
Fuel heater is located in FUEL FILTER/WATER SEPARATOR &
WATER-IN-FUEL SENSOR. See FUEL FILTER/WATER SEPARATOR & WATER-IN-FUEL
SENSOR.
FUEL INJECTOR
Removal
1) Disconnect negative battery cables. Each fuel injector is
connected to each high-pressure fuel line with a steel connector line.
Steel connector is positioned into cylinder head and sealed with "O"
ring. See Fig. 8. If removing injector at cylinder No. 1 or No. 2,
remove intake manifold air heater assembly. If removing injector at
cylinder No. 5, remove engine lifting bracket. Ensure area around fuel
injector and high-pressure fuel line is clean. Disconnect high-
pressure fuel line at fuel injector. DO NOT bend any high-pressure
fuel line to gain access to fuel injector. It may be necessary to
remove high-pressure fuel lines from fuel injection pump for access to
fuel injector.
2) If removing high-pressure fuel lines from fuel injection
pump, mark high-pressure fuel line location for installation
reference. Remove valve cover. Thread Fuel Injector Connector Tube
Remover (8324) onto end of injector connector tube. Remove and discard\
old "O" ring from injector connector tube.
3) Remove fuel injector hold down clamp bolt at front end of
clamp. DO NOT loosen or remove shouldered bolt at rear of clamp.
Remove injector clamp by sliding it from shoulders on rear clamp bolt.
Thread rod from fuel injector remover into top of fuel injector.
Tighten nut to remove fuel injector from cylinder head. Remove and
discard "O" ring and copper sealing washer.
Fig. 8: Removing Fuel Injector
Courtesy of Chrysler Corp.
Installation
1) Clean fuel injector bore on cylinder head with wire brush.

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.

Removal & Installation
See INTAKE MANIFOLD AIR HEATER RELAYS under RELAYS &
SOLENOIDS.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Access Plug ................................................ 11 (15)\
AFC Line-To-Fuel Injection Pump Fitting .................... 18 (24)\
Air Inlet Housing Bolt ..................................... 18 (24)\
Engine Bracket-To-Engine Bolts ............................. 18 (24)\
Engine Coolant Temperature Sensor .......................... 40 (54)\
Engine Speed Sensor Nut .................................... 18 (24)\
Fuel Injection Pump Drive Gear Nut ....................... 125 (170)\
Fuel Injection Pump Lower Bracket-To-Pump Bolts ............ 18 (24)\
Fuel Injection Pump Mount Nuts ............................. 32 (43)\
Fuel Injector Retaining Nut ................................ 44 (60)\
Fuel Line-To-Fuel Heater Fitting ........................... 18 (24)\
Fuel Line-To-Fuel Transfer Pump ............................ 18 (24)\
Fuel Supply Line Banjo Bolt ................................ 18 (24)\
Fuel Tank Strap Nut ........................................ 30 (41)\
Fuel Transfer Pump Bolt .................................... 18 (24)\
High-Pressure Fuel Line Clamp Bolt ......................... 18 (24)\
High-Pressure Fuel Line Nut (At Injector) .................. 28 (38\
)
High-Pressure Fuel Line Nut (At Pump) ...................... 18 (24\
)
Intake Manifold Air Heater Housing Bolt .................... 18 (24)\
Intake Manifold Air Temperature Sensor ..................... 20 (27)\
Intake Manifold Cover Bolt ( 1) ............................. 18 (24)
Oil Fill Plug .............................................. 21 (29)\
Overflow Valve-To-Fuel Injection Pump ...................... 24 (33)\
Park/Neutral Switch ........................................ 25 (34)\
Plastic Fuel Tank Module Lock Nut .......................... 32 (43)\
Starter Mounting Bolt ...................................... 32 (43)\
Turbocharger Oil Drain Line Bolt ........................... 18 (24)\
Turbocharger Oil Supply Line Nut ........................... 11 (15)\
Turbocharger Retaining Nut ................................. 24 (33)\
INCH Lbs. (N.m)
Air Inlet Tube-To-Turbocharger Clamp Nut .................. 72 (8.1)\
Canister Nut ............................................ 120 (13.6)\
Condenser-To-Intercooler Nut ............................. 95 (10.7)\
Condenser-To-Intercooler Screw ........................... 95 (10.7)\
Drain Valve-To-Canister Bolt .............................. 40 (4.5)\
Exhaust Pipe-To-Turbocharger Clamp Nut .................... 72 (8.1)\
Fuel Bleed Bolt ........................................... 72 (8.1)\
Fuel Injector Drain Line Assembly Retaining Clamp Bolt .. 120 (13.6)\
Fuel Injector Drain Line-To-Fuel Injector Banjo Bolt ...... 84 (9.5)\
Intake Manifold Air Heater Relay Assembly Retaining Bolt .. 40 (4.5)\
Intercooler Bolt .......................................... 17 (1.9)\
Intercooler Inlet & Outlet Duct Clamp ..................... 72 (8.1)\
PCM Mounting Bolt ......................................... 35 (4.0)\
Water-In-Fuel (WIF) Sensor ................................ 20 (2.3\
)
( 1) - Apply thread sealant to bolt threads.









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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

bracket. Ensure alignment tab on brake switch aligns with opening on
mounting bracket.
CAUTION: When adjusting brake switch, DO NOT pull brake pedal back
toward brake switch with excessive pressure, or brake switch
may be damaged.
3) When brake switch is fully installed in mounting bracket,
rotate brake switch clockwise approximately 30 degrees. To ensure
proper brake switch adjustment, gently pull brake pedal back toward
brake switch as far as possible. DO NOT apply excessive pressure on
brake pedal and brake switch.
Removal (Ram Van & Ram Wagon)
1) Brake switch is located near top of brake pedal. Remove
lower steering column cover. Remove data link connector, hood release
lever and parking brake lever from lower instrument panel cover.
2) Remove lower instrument panel cover for access to brake
switch. Depress and hold brake pedal downward. Rotate brake switch
counterclockwise approximately 1/16 turn to so locking collar on brake
switch aligns with opening on mounting bracket. Pull brake switch
rearward from mounting bracket. Disconnect electrical connector from
brake switch.
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
bracket. Ensure locking collar on brake switch aligns with opening on
mounting bracket.
CAUTION: When adjusting brake switch, DO NOT pull brake pedal back
toward brake switch with excessive pressure, or brake switch
may be damaged.
3) When brake switch is fully installed in mounting bracket,
rotate brake switch clockwise approximately 1/16 turn. To ensure
proper brake switch adjustment, gently pull brake pedal back toward
brake switch as far as possible. DO NOT apply excessive pressure on
brake pedal and brake switch.
CAMSHAFT POSITION SENSOR
Removal & Installation
See CAMSHAFT POSITION SENSOR under IGNITION SYSTEM.
CRANKSHAFT POSITION SENSOR
Removal & Installation
See CRANKSHAFT POSITION SENSOR under IGNITION SYSTEM.
DOWNSTREAM OXYGEN SENSOR
NOTE: Downstream oxygen sensor may also be referred to as post
-catalyst oxygen sensor.

Removal
Downstream oxygen sensor is mounted on exhaust pipe, behind
catalytic converter. Raise and support vehicle. Disconnect electrical
connector for downstream oxygen sensor. Using Socket (YA8875), remove
downstream oxygen sensor from exhaust pipe.
Installation
If installing original or used downstream oxygen sensor,
apply anti-seize compound on threads of downstream oxygen sensor. A
NEW downstream oxygen sensor should already be coated with anti-seize
compound. Install and tighten downstream oxygen sensor to
specification. See TORQUE SPECIFICATIONS. Install electrical
connector.
ENGINE COOLANT TEMPERATURE SENSOR
Removal & Installation (Dakota 2.5L)
1) Partially drain cooling system. Disconnect electrical
connector at engine coolant temperature sensor. Engine coolant
temperature sensor is located on side of thermostat housing and
contains a Tan/Black wire and a Black/Light Blue wire in the
electrical connector.
2) Remove engine coolant temperature sensor. To install,
reverse removal procedure. Tighten engine coolant temperature sensor
to specification. See TORQUE SPECIFICATIONS. Fill cooling system.
Removal (Dakota 3.9L, 5.2L & 5.9L, Durango & Ram Pickup 3.9L,
5.2L & 5.9L)
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) Remove air cleaner if necessary for access to engine
coolant temperature sensor. On models equipped with A/C, go to next
step. On models not equipped with A/C, disconnect electrical connector
at engine coolant temperature sensor. Remove engine coolant
temperature sensor.
3) On A/C equipped models, electrical connector on engine
coolant temperature sensor may be difficult to reach. 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.
Removal & Installation (Ram Pickup 8.0L)
1) Partially drain cooling system. Engine coolant temperature
sensor is located on front of intake manifold, near rear of generator
and contains a Tan/Black wire and a Black/Light Blue wire in the
electrical connector.
2) Disconnect electrical connector at engine coolant
temperature sensor. Remove engine coolant temperature sensor.
3) To install, reverse removal procedure. Tighten engine
coolant temperature sensor to specification. See TORQUE
SPECIFICATIONS. Fill cooling system.
Removal (Ram Van & Ram Wagon)

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.

Fig. 5: Locating Intake Air Temperature (IAT) Sensor (Dakota 3.
9L, 5.2L & 5.9L, Durango, Ram Pickup 3.9L, 5.2L, & 5.9L, Ram Van & Ram
Wagon)
Courtesy of Chrysler Corp.
Fig. 6: Locating Intake Air Temperature (IAT) Sensor (Ram Pickup
8.0L)
Courtesy of Chrysler Corp.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR