rear light DODGE RAM 1500 1998 2.G Owners Manual

OIL COOLER & LINES
CLEANING
CLEANING AND INSPECTION
Clean the sealing surfaces.
Apply 483 kPa (70 psi) air pressure to the element
to check for leaks. If the element leaks, replace the
element.
OIL FILTER
REMOVAL
(1) Clean the area around the oil filter head.
Remove the filter from below using a cap-style filter
wrench.
(2) Clean the gasket surface of the filter head. The
filter canister O-Ring seal can stick on the filter
head. Make sure it is removed.
INSTALLATION
(1) Fill the oil filter element with clean oil before
installation. Use the same type oil that will be used
in the engine.
(2) Apply a light film of lubricating oil to the seal-
ing surface before installing the filter.
CAUTION: Mechanical over-tightening may distort
the threads or damage the filter element seal.
(3) Install the filter until it contacts the sealing
surface of the oil filter adapter. Tighten filter an
additional
1¤2turn.
OIL PAN
REMOVAL
(1) Disconnect the battery negative cables.
(2) Install engine support fixture # 8534.
(3) Raise vehicle on hoist.
(4) Disconnect starter cables from starter motor.
(5) Remove transmission and transfer case (if
equipped).
(6) Remove flywheel or flexplate.
(7) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
and transmission adapter plate assembly.
WARNING: HOT OIL CAN CAUSE PERSONAL
INJURY.
(8) Drain the engine oil (Refer to 9 - ENGINE/LU-
BRICATION/OIL - STANDARD PROCEDURE).(9) Install the oil pan drain plug if sealing surface
is not damaged and tighten to 50 N´m (37 ft. lbs.)
torque.
(10) Remove oil pan bolts, break the pan to block
seal, and lower pan slightly and remove oil suction
tube fasteners.
(11) Remove oil pan and suction tube.
CLEANING
Remove all gasket material from the oil pan and
cylinder block sealing surfaces. Extra effort may be
required around T-joint areas. Clean oil pan and
flush suction tube with a suitable solvent.
INSPECTION
Inspect the oil pan, suction tube, and tube braces
for cracks and damage. Replace any defective compo-
nent. Inspect the oil drain plug and drain hole
threads. Inspect the oil pan sealing surface for
straightness. Repair any minor imperfections with a
ball-peen hammer. Do not attempt to repair an oil
pan by welding.
INSTALLATION
(1) Fill the T-joint between the pan rail/gear hous-
ing and pan rail/rear seal retainer with sealant. Use
MopartSilicone Rubber Adhesive Sealant or equiva-
lent.
(2) Place suction tube in oil pan and guide them
into place. Using a new tube to block gasket, install
and tighten the suction tube bolts by hand. Starting
with the oil pump inlet bolts, tighten the bolts to 24
N´m (18 ft. lbs.) torque. Tighten the remaining tube
brace bolts to 43 N´m (32 ft. lbs.) torque.
(3) Starting in the center and working outward,
tighten the oil pan bolts to 28 N´m (21 ft. lbs.)
torque.
(4) Install the flywheel housing assembly with the
starter motor attached and tighten bolts to 77 N´m
(57 ft. lbs.) torque.
(5) Connect starter motor cables.
(6) Install the flywheel or flexplate. Torque to 137
N´m (101 ft. lbs.).
(7) Install transmission and transfer case (if
equipped).
(8) Lower vehicle.
(9) Remove the engine support fixture # 8534.
(10) Install battery negative cables.
(11) Fill the crankcase with new engine oil.
(12) Start engine and check for leaks. Stop engine,
check oil level, and adjust, if necessary.
DRENGINE 5.9L DIESEL 9 - 293

FRAMES & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT AIR DAM
REMOVAL.............................2
INSTALLATION..........................2
FRONT BUMPER
REMOVAL.............................2
INSTALLATION..........................2
FRONT FASCIA
REMOVAL.............................2
INSTALLATION..........................3
REAR BUMPER
REMOVAL.............................3
INSTALLATION..........................4
FRAME
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 4
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY
FRONT FRAME RAIL TIP REPLACEMENT....4
STANDARD PROCEDURE - HYDROFORM
FENDER RAIL REPAIR.................11
STANDARD PROCEDURE - REAR FRAME
H-SECTION REPLACEMENT.............13SPECIFICATIONS
SPECIFICATIONS - WELD PROCESS......15
SPECIFICATIONS - FRAME DIMENSIONS . . . 16
SPECIFICATIONS - TORQUE............22
FRONT CROSSMEMBER
REMOVAL.............................22
INSTALLATION.........................22
FRONT SKID PLATE
REMOVAL.............................23
INSTALLATION.........................23
FRONT TOW HOOK ASSEMBLY
REMOVAL.............................23
INSTALLATION.........................23
TRANSMISSION CROSSMEMBER
REMOVAL.............................24
INSTALLATION.........................24
TRAILER HITCH
REMOVAL.............................25
INSTALLATION.........................25
TRANSFER CASE SKID PLATE
REMOVAL.............................26
INSTALLATION.........................26
BUMPERS
SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper center bracket nuts 95 70 Ð
Front bumper stud plate nuts 95 70 Ð
License plate hitch reinforcement bolts 54 40 Ð
Rear bumper support bracket stud plate nuts 54 40 Ð
Rear bumper support bracket to hitch bolts 54 40 Ð
Rear bumper to hitch bolts 54 40 Ð
DRFRAMES & BUMPERS 13 - 1

SPORT FASCIA REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the three screws at each trailing edge
of the fascia. (Fig. 3)
(3) Remove the five lower screws.
(4) Remove and discard the four upper push pins.
(5) Using a trim stick C-4755 or equivalent, care-
fully release the six lower clips and remove the close
out panel.
(6) Using a trim stick C-4755 or equivalent, care-
fully remove the step pad.
(7) Spread the fascia out at the wheels and remove
from the vehicle.
INSTALLATION
NOTE: The left and right inboard bumper to bracket
attachments must be secured before installing the
fascia and step pad.
ST/SLT/SLT+ FASCIA INSTALLATION
(1) Install the fascia.
(2) Position the close out panel and seat the 6
lower clips fully.
(3) Install four new upper push pin fasteners.
(4) Position the step pad onto the fascia and fully
seat the attachment clips.(5) Align the fascia to the fender with a 19 mm
(0.75 inch) gap and install the two screws at each
trailing edge of the fascia.
SPORT FASCIA INSTALLATION
(1) Position the fascia onto the bumper.
(2) Position the step pad onto the fascia and fully
seat the attachment clips.
(3) Install four new upper push pin fasteners.
(4) Install the five lower screws.
(5) Install the three screws at each trailing edge of
the fascia.
REAR BUMPER
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the license plate.
(3) Remove the bolts behind the plate.
(4) Disconnect the license plate light electrical con-
nectors.
(5) Disconnect the trailer light connector electrical
connection, if equipped.
(6) Remove the two bolts along the front upper
edge of the bumper near the frame tips.
(7) Support the bumper with a suitable lifting
device.
(8) Remove the bolts attaching the bumper support
brackets to the trailer hitch. (Fig. 4)
Fig. 3 SPORT FASCIA
1 - STEP PAD
2 - FASCIA (SPORT MODEL ONLY)
3 - SCREWS (3 PER SIDE)
4 - UPPER FASCIA SUPPORT BRACKET
5 - WHEELHOUSE SPLASH SHIELD BRACKET
6 - INBOARD BUMPER BRACKET ATTACHMENTS
7 - PUSH PIN FASTENERS (4)
8 - LOWER SCREWS (5)
Fig. 4 TRAILER HITCH
1 - HITCH
2 - LD HITCH BOLTS (4)/HD (6)
3 - BUMPER BRACKET BOLTS (4)
4 - BUMPER SUPPORT BRACKETS
DRFRAMES & BUMPERS 13 - 3
FRONT FASCIA (Continued)

INSTALLATION
(1) Align the holes in the bumpers to the trailer
hitch pins and install the bumper.
(2) Install the support bracket to the hitch bolts,
loosely.
(3) Install the front upper edge to the trailer hitch
bolts and tighten to 54 N´m (40 ft. lbs.).
(4) Install the license plate reinforcement to hitch
bolts and tighten to 54 N´m (40 ft. lbs.).
(5) Tighten the left bumper bracket bolts to 54
N´m (40 ft. lbs.).
(6) Tighten the right bumper bracket bolts to 54
N´m (40 ft. lbs.).
(7) Connect the trailer light connector electrical
connection, if equipped.
(8) Connect the license plate light electrical con-
nectors.
(9) Install the license plate.
FRAME
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT.
²BEFORE PROCEEDING WITH FRAME REPAIR
INVOLVING GRINDING OR WELDING, VERIFY THAT
VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN
CONTACT WITH REPAIR AREA, PERSONAL INJURY
CAN RESULT.
²DO NOT ALLOW OPEN FLAME OR HEAT AND
METAL SPATTER FROM ARC WELDING, TO CON-
TACT PLASTIC BODY PANELS. FIRE OR EXPLO-
SION CAN RESULT.
²WHEN WELDED FRAME COMPONENTS ARE
REPLACED, ENSURE COMPLETE PENETRATION
WELD IS ACHIEVED DURING INSTALLATION. IF
NOT, DANGEROUS OPERATING CONDITIONS CAN
RESULT.
²STAND CLEAR OF CABLES OR CHAINS ON
PULLING EQUIPMENT DURING FRAME STRAIGHT-
ENING OPERATIONS, PERSONAL INJURY CAN
RESULT.
²DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT SUPPORTED ON SAFETY
STANDS, PERSONAL INJURY CAN RESULT.
CAUTION: 1500 series Dodge Ram Trucks (2002 and
later) are not designed for snow plow equipment.The front collision repair tips must not be installed
on any truck equipped with a snow plow, or even
intended to be equipped with a snow plow.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Failure to use only pro-
duction fasteners or fasteners of equivalent hard-
ness can result in loosening or failure. Do not drill
any holes in the frame that are not specifically out-
lined in this or other, DaimlerChrysler procedure as
frame rail failure can result. When using heat to
straighten frame components do not exceed 566ÉC
(1050ÉF), metal fatigue can result.
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY FRONT
FRAME RAIL TIP REPLACEMENT
CAUTION: This procedure is designed to replace
the front frame rail tips that have been damaged in
the crush initiator zones. Prior to any cutting, the
vehicle must be mounted on the appropriate frame
repair equipment (ªframe rackº), checked with three
dimensional measuring equipment, and the neces-
sary pull corrections made. If damage remains in
the frame beyond the area covered by this service
part after the pull, the frame must be replaced in its
entirety.
NOTE: Procedures for 4X2 and 4X4 are common
except as noted in this procedure.
(1) Before proceding with this repair procedure
review the required service warnings and precau-
tions. (Refer to 13 - FRAME & BUMPERS/FRAME -
WARNING)
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the front wheelhouse splash shield.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL-
HOUSE SPLASH SHIELD - REMOVAL)
(4) Remove the bolts and position aside the wire
harness and grounds, if required.
(5) Remove the front bumper. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT BUMPER
- REMOVAL)
(6) Loosen and lower the stabilizer bar mount and
bar. (Refer to 2 - SUSPENSION/FRONT/STABI-
LIZER BAR - REMOVAL)
13 - 4 FRAMES & BUMPERSDR
REAR BUMPER (Continued)

SERVICE SLEEVE ASSEMBLY
NOTE: Two sleeve halves are included with each
kit. Modifications as follow, are necessary to create
the correct sleeve assembly for each application.
(1) On 4X2 models, the9lower9sleeve is made by
cutting off the tab and cutting out a notch in the bot-
tom sleeve portion. Round the corners of the cut out
to keep stress cracks from forming. On 4X4 models
the9lower9sleeve is used as provided. (Fig. 15)
(2) On both 4X2 and 4X4 models cut off the front
tab on the upper sleeve portion. (Fig. 16)(3) The sleeve halves are shipped slightly over-
sized to allow custom fitting to each replacement
frame rail tip. It is necessary to grind the mating
surfaces to achieve the desired snug fit into the
replacement tip (rail tube has increasing height rear-
ward of the cut line). Once the two sleeve halves are
fitted, bevel the edges 25É - 30É.
NOTE: Scribing a line 2 mm from the cut edge and
then grinding back to the mark will simplify the
bevel creation process and accuracy.
(4) Remove any burrs at the beveled edges.
(5) Using the Weld Process Specifications table
(Refer to 13 - FRAME & BUMPERS/FRAME - SPEC-
IFICATIONS - WELDING), weld the two halves of
the repair sleeve together. (Fig. 17)
(6) Clean the welds of any flux and other impuri-
ties and grind smooth before proceeding with the
installation of the sleeve.
(7) Find the centerline of the sleeve and scribe a
centerline mark. Mark two additional lines 2 mm
(0.08 in.) on either side of the centerline mark to help
ensure the required 4 mm-6mm(0.16 in. - 0.24 in.)
weld root gap. (Fig. 17)
Fig. 15 4X2 LOWER SLEEVE CUT LOCATION
1 - SERVICE SLEEVE LOWER HALF
2 - CUT DIMENSION 27 mm (1.06 in.)
3 - CUT DIMENSION 36.1 mm (1.42 in)
4 - 4X2 CUTOUT
5 - FRONT TAB CUT LINE (4X2 ONLY)
Fig. 16 UPPER SLEEVE CUT LOCATION
1 - SERVICE SLEEVE UPPER HALF
2 - CUT LOCATION
Fig. 17 SERVICE SLEEVE ASSEMBLY
1 - CENTERLINE SCRIBE MARK
2 - WELD SEAM
3 - REAR TAB (4X4 ONLY)
4 - SCRIBE LINE LOCATION 2 mm (0.08 in.)
5 - FRONT TAB (4X4 ONLY)
13 - 10 FRAMES & BUMPERSDR
FRAME (Continued)

SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Cab mount bolts 81 60 Ð
Cargo box bolts 108 80 Ð
Front crossmember bolts - 2WD (light duty only) 61 45 Ð
Front crossmember bolts - 2WD (heavy duty only) 75 55 Ð
Front crossmember bolts - 4WD (light duty only) 102 75 Ð
Front skid plate bolts 34 25 Ð
Lower bumper support bracket bolt 54 40 Ð
Radiator crossmember bolts - lower 28 21 Ð
Radiator crossmember bolts - upper 28 21 Ð
Rear crossmember (light duty only) 102 75 Ð
Rear crossmember (heavy duty only) 115 85 Ð
Rear spring shackle bolts 163 120 Ð
Spare tire winch bolts 41 30 Ð
Trailer hitch reinforcement bracket bolt 170 125 Ð
Transfercase skid plate bolts 34 25 Ð
Transercase skid plate crossmember bolts 34 25 Ð
Transmission mount to crossmember nuts 54 40 Ð
FRONT CROSSMEMBER
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the front skid plate, if equipped. (Refer
to 13 - FRAME & BUMPERS/FRAME/FRONT SKID
PLATE - REMOVAL)
(3) Remove the bolts and remove the crossmember.
(Fig. 28) or (Fig. 29)
INSTALLATION
(1) Install the crossmember.
(2) Install the bolts;
²On light duty 2WD vehicles, tighten the bolts to
61 N´m (45 ft. lbs.).
²On light duty 4WD vehicles, tighten the bolts to
102 N´m (75 ft. lbs.).
²On heavy duty 2WD vehicles, tighten the bolts
to 75 N´m (55 ft. lbs.).
(3) Install the front skid plate, if equipped. (Refer
to 13 - FRAME & BUMPERS/FRAME/FRONT SKID
PLATE - INSTALLATION)
Fig. 28 FRONT CROSSMEMBER - 2WD
1 - CROSSMEMBER
2 - BOLTS (2 PER SIDE)
13 - 22 FRAMES & BUMPERSDR
FRAME (Continued)

TRANSMISSION
CROSSMEMBER
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the transfercase skid plate, if
equipped. (Refer to 13 - FRAME & BUMPERS/
FRAME/TRANSFER CASE SKID PLATE -
REMOVAL)
(3) Support the transmission with a suitable lifting
device.
(4) Remove the transmission mount nuts. (Fig. 33)
or (Fig. 34)
(5) Remove the bolts and remove the crossmember.
INSTALLATION
(1) Install the crossmember and install the bolts.
²On light duty vehicles, tighten the bolts to 102
N´m (75 ft. lbs.).
²On heavy duty vehicles, tighten the bolts to 115
N´m (85 ft. lbs.).
(2) Install the transmission mount nuts and
tighten to 54 N´m (40 ft. lbs.).(3) Remove the transmission support.
(4) Install the transfercase skid plate. (Refer to 13
- FRAME & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION)
Fig. 32 FRONT TOW HOOK ASSEMBLY ± HEAVY
DUTY
1 - BOLTS (4 PER HOOK)
2 - HEAVY DUTY TOW HOOKS (2)
3 - BUMPER CENTER SUPPORT BRACKETS
Fig. 33 REAR CROSSMEMBER - 2WD
1 - TRANSMISSION MOUNT
2 - REAR CROSSMEMBER
3 - TRANSMISSION MOUNT NUTS (2)
4 - CROSSMEMBER BOLTS (2 PER SIDE)
Fig. 34 REAR CROSSMEMBER - 4WD
1 - TRANSMISSION MOUNT
2 - TORSION BAR
3 - CROSSMEMBER BOLTS (3 PER SIDE)
4 - REAR CROSSMEMBER
5 - TRANSMISSION MOUNT NUTS (2)
13 - 24 FRAMES & BUMPERSDR
FRONT TOW HOOK ASSEMBLY (Continued)

TRAILER HITCH
REMOVAL
(1) Remove the rear bumper. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/REAR BUMPER -
REMOVAL)
(2) Remove the hitch bolts. (Fig. 35) and (Fig. 36)
(3) Disconnect all wire harness support push pins.
(4) Remove the rear two cargo box bolts and loosen
the remaining bolts. (Refer to 23 - BODY/EXTERI-
OR/CARGO BOX - REMOVAL)
(5) Using a suitable lifting device, lift and support
the rear of the cargo box and remove the hitch.
INSTALLATION
(1) Install the hitch onto the frame rails and make
sure the locators on the inside of the hitch brackets
are engaged with the holes in the top of the frame
rails properly.
(2) Lower the cargo box and install the rear bolts.
(Refer to 23 - BODY/EXTERIOR/CARGO BOX -
INSTALLATION)
(3) Install the hitch bolts and tighten to 170 N´m
(125 ft. lbs.).
(4) Connect all wire harness support push pins.
(5) Install the rear bumper. (Refer to 13 - FRAME
& BUMPERS/BUMPERS/REAR BUMPER - INSTAL-
LATION)
Fig. 35 TRAILER HITCH ± LIGHT DUTY
1 - LOCATING TAB HOLE
2 - LOCATING PIN HOLE
3 - U-NUTS (2)
4 - BUMPER SUPPORT BRACKETS5 - HITCH
6 - BUMPER BRACKET BOLTS (4)
7 - HITCH BOLTS (4)
DRFRAMES & BUMPERS 13 - 25

(15) Install air duct to air box.
(16) Connect battery cable to battery.
(17) Start engine and check for leaks.
5.7L V-8
(1) If fuel injectors are to be installed, refer to Fuel
Injector Removal/Installation.
(2) Clean out fuel injector machined bores in
intake manifold.
(3) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(4) Position fuel rail/fuel injector assembly to
machined injector openings in intake manifold.
(5) Guide each injector into intake manifold. Be
careful not to tear injector o-rings.
(6) Pushrightside of fuel rail down until fuel
injectors have bottomed on shoulders. Pushleftfuel
rail down until injectors have bottomed on shoulders.
(7) Install 4 fuel rail holdown clamps and 4 mount-
ing bolts. Refer to Torque Specifications.
(8) Position spark plug cable tray and cable assem-
bly to intake manifold. Snap 4 cable tray retaining
clips into intake manifold.
(9) Install all cables to spark plugs and ignition
coils.
(10) Connect electrical connector to throttle body.
(11) Install electrical connectors to all 8 ignition
coils. Refer to Ignition Coil Removal/Installation.
(12) Connect electrical connector to throttle body.
(13) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 17). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector.
(14) Connect fuel line latch clip and fuel line to
fuel rail. Refer to Quick-Connect Fittings.
(15) Install air resonator to throttle body (2 bolts).
(16) Install flexible air duct to air box.
(17) Connect battery cable to battery.
(18) Start engine and check for leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module, and (if equipped) cer-
tain ORVR components.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.Two check (control) valves are mounted into the
top of the fuel tank. Refer to Fuel Tank Check Valve
for additional information.
An evaporation control system is connected to the
fuel tank to reduce emissions of fuel vapors into the
atmosphere. When fuel evaporates from the fuel
tank, vapors pass through vent hoses or tubes to a
charcoal canister where they are temporarily held.
When the engine is running, the vapors are drawn
into the intake manifold. Certain models are also
equipped with a self-diagnosing system using a Leak
Detection Pump (LDP) and/or an On-Board Refueling
Vapor Recovery (ORVR) system. Refer to Emission
Control System for additional information.
REMOVAL- EXCEPT DIESEL
Fuel Tank Draining
WARNING: THE FUEL SYSTEM MAY BE UNDER
CONSTANT FUEL PRESSURE EVEN WITH THE
ENGINE OFF. THIS PRESSURE MUST BE
RELEASED BEFORE SERVICING FUEL TANK.
Two different procedures may be used to drain fuel
tank: through the fuel fill fitting on tank, or using
the DRBtscan tool. Due to a one-way check valve
installed into the fuel fill opening fitting at the tank,
the tank cannot be drained conventionally at the fill
cap.
The quickest draining procedure involves removing
the rubber fuel fill hose.
As an alternative procedure, the electric fuel pump
may be activated allowing tank to be drained at fuel
rail connection. Refer to DRB scan tool for fuel pump
activation procedures. Before disconnecting fuel line
at fuel rail, release fuel pressure. Refer to the Fuel
System Pressure Release Procedure for procedures.
Attach end of special test hose tool number 6541,
6539, 6631 or 6923 at fuel rail disconnection (tool
number will depend on model and/or engine applica-
tion). Position opposite end of this hose tool to an
approved gasoline draining station. Activate fuel
pump and drain tank until empty.
If electric fuel pump is not operating, fuel must be
drained through fuel fill fitting at tank. Refer to fol-
lowing procedures.
(1) Release fuel system pressure.
(2) Raise vehicle.
(3) Thoroughly clean area around fuel fill fitting
and rubber fuel fill hose at tank.
(4) If vehicle is equipped with 4 doors and a 6 foot
(short) box, remove left-rear tire/wheel.
(5) Loosen clamp (Fig. 23) and disconnect rubber
fuel fill hose at tank fitting. Using an approved gas
holding tank, drain fuel tank through this fitting.
DRFUEL DELIVERY - GAS 14 - 17
FUEL RAIL (Continued)

(2) Apply a small amount of engine oil to sensor
o-ring.
(3) Install sensor into engine block with a slight
rocking and twisting action.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) Install mounting bolt and tighten to 28 N´m
(21 ft. lbs.) torque.
(5) Connect electrical connector to sensor.
(6) Lower vehicle.
4.7L V-8
(1) Clean out machined hole in engine block.
(2) Apply a small amount of engine oil to sensor
o-ring.
(3) Install sensor into engine block with a slight
rocking and twisting action.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) Install mounting bolt and tighten to 28 N´m
(21 ft. lbs.) torque.
(5) Connect electrical connector to sensor.(6) Lower vehicle.
5.7L V-8
(1) Clean out machined hole in engine block.
(2) Apply a small amount of engine oil to sensor
o-ring.
(3) Install sensor into engine block with a slight
rocking and twisting action.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) Install mounting bolt and tighten to 28 N´m
(21 ft. lbs.) torque.
(5) Connect electrical connector to sensor.
(6) Lower vehicle.
FUEL INJECTOR
DESCRIPTION
An individual fuel injector (Fig. 11) is used for each
individual cylinder.
OPERATION
OPERATION - FUEL INJECTOR
The top (fuel entry) end of the injector (Fig. 11) is
attached into an opening on the fuel rail.
The fuel injectors are electrical solenoids. The
injector contains a pintle that closes off an orifice at
the nozzle end. When electric current is supplied to
the injector, the armature and needle move a short
distance against a spring, allowing fuel to flow out
the orifice. Because the fuel is under high pressure, a
fine spray is developed in the shape of a pencil
Fig. 10 CKP REMOVAL / INSTALLATION - 5.7L V-8
1 - CYLINDER BLOCK - RIGHT / REAR
2 - ELEC. CONNECTOR
3 - MOUNTING BOLT
4 - CKP SENSOR
Fig. 11 FUEL INJECTOR
1 - FUEL INJECTOR
2 - NOZZLE
3 - TOP (FUEL ENTRY)
14 - 26 FUEL INJECTION - GASDR
CRANKSHAFT POSITION SENSOR (Continued)