tow DODGE RAM 1999 Service Owners Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 980 of 1691
Fig. 28. Fuel tank must be removed for servicing of fuel pump module.
Remove fuel tank. See FUEL TANK under FUEL SYSTEM.
2) Ensure area around fuel pump module is clean. Rotate fuel
filter/pressure regulator so fuel line fitting on side fuel
filter/fuel pressure regulator points toward center of fuel pump
module.
3) Note location of metal fuel pump module lock ring and
locking fingers on the fuel tank. See Fig. 34. There are 6 locking
fingers molded into the plastic fuel tank.
4) Apply a small amount of engine oil on each locking finger
at the fuel pump module lock ring area. Engine oil will act as a
lubricant when removing fuel pump module lock ring.
5) Note location of lock tab on fuel pump module lock ring.
Pry lock tab backward while using a hammer and brass drift to tap fuel
pump module lock ring counterclockwise. Remove fuel pump module lock
ring, fuel pump module and rubber gasket from fuel tank.
CAUTION: When fuel pump module is removed from fuel tank, rubber
gasket must be replaced. DO NOT reuse rubber gasket.
Installation
1) Ensure sealing area on fuel tank is clean. Using NEW
rubber gasket, install fuel pump module on fuel tank. DO NOT reuse
rubber gasket. Ensure rubber gasket remains in place.
NOTE: Fuel pump module must be properly positioned in fuel tank to
prevent float from contacting the fuel tank.
2) Rotate fuel pump module so fuel pump is properly
positioned in the fuel tank. See Fig. 34. Apply a small amount of
engine oil on each locking finger at fuel pump module lock ring area.
Install fuel pump lock ring on fuel pump module.
3) Using a hammer and brass drift, tap fuel pump module lock
ring clockwise until the 6 locking fingers engage in fuel pump module
lock ring and lock tab engages notch on fuel pump module lock ring.
Ensure lock tab fully engages with notch on fuel pump module lock
ring. Reinstall fuel tank using proper procedure.
Fig. 34: Locating Fuel Pump Module Lock Ring, Locking Fingers &
Positioning Fuel Pump Module In Fuel Tank (Durango)
Courtesy of Chrysler Corp.
Removal (Ram Pickup)
Page 981 of 1691
1) Fuel pump module is located on top of fuel tank. See
Fig. 29. Fuel tank must be removed for servicing of fuel pump module.
Remove fuel tank. See FUEL TANK under FUEL SYSTEM.
2) Ensure area around fuel pump module is clean. Note
position of fuel pump module installation in fuel tank for
installation reference. Using Fuel Pump Module Lock Nut Spanner Wrench
(6856), remove fuel pump module lock nut. See Fig. 32. Remove fuel
pump module with rubber gasket from fuel tank.
CAUTION: When fuel pump module is removed from fuel tank, rubber
gasket must be replaced. DO NOT reuse rubber gasket.
Installation
1) Ensure sealing area on fuel tank is clean. Using NEW
rubber gasket, install fuel pump module on fuel tank. DO NOT reuse
rubber gasket. Ensure rubber gasket remains in place.
NOTE: Fuel pump module must be properly positioned in fuel tank to
prevent float from contacting the fuel tank.
2) Loosely install fuel pump module lock nut. Rotate fuel
pump module so electrical connector is pointing toward driver's side
of fuel tank. See Fig. 29.
3) Note location of fuel pressure regulator on fuel pump
module. See Fig. 29. Ensure fuel filter/pressure regulator is
positioned on fuel pump module so fuel line fitting on side fuel
filter/fuel pressure regulator points toward driver's side of fuel
tank.
4) Hold fuel pump module in place while tightening fuel pump
module lock nut to specification. See TORQUE SPECIFICATIONS. Reinstall
fuel tank using proper procedure.
Removal (Ram Van & Ram Wagon)
1) Fuel pump module is located on top of fuel tank. See
Fig. 30 . Fuel tank must be removed for servicing of fuel pump module.
Remove fuel tank. See FUEL TANK.
2) Ensure area around fuel pump module is clean. Using Fuel
Pump Module Lock Nut Spanner Wrench (6856), remove fuel pump module
lock nut. See Fig. 32. Remove fuel pump module with rubber gasket from
fuel tank.
CAUTION: When fuel pump module is removed from fuel tank, rubber
gasket must be replaced. DO NOT reuse rubber gasket.
Installation
1) Ensure sealing area on fuel tank is clean. Using NEW
rubber gasket, install fuel pump module on fuel tank. DO NOT reuse
rubber gasket. Ensure rubber gasket remains in place.
NOTE: Fuel pump module must be properly positioned in fuel tank to
prevent float from contacting the fuel tank.
2) Rotate fuel pump module so alignment mark on fuel pump
module aligns with reference mark on fuel tank. See Fig. 35. Install
and hand tighten fuel pump module lock nut.
3) Note location of fuel pressure regulator on fuel pump
module. See Fig. 35. Ensure fuel filter/pressure regulator is
positioned on fuel pump module so fuel line fitting on side fuel
filter/fuel pressure regulator points toward driver's side of vehicle.
4) Hold fuel pump module in place while tightening fuel pump
module lock nut to specification. See TORQUE SPECIFICATIONS. Reinstall
fuel tank using proper procedure.
Page 983 of 1691
line on fuel rail using proper procedure. Go to step 5).
4) Release fuel pressure from fuel system. See FUEL SYSTEM
PRESSURE RELEASE. Ensure negative battery cable is disconnected.
Remove fuel tank cap to release any residual fuel tank pressure.
5) Open fuel tank filler door. Fuel tank filler tube assembly
is mounted to a plastic bezel behind fuel tank filler door. See
Fig. 36. Note location of bezel-to-body screw. See Fig. 36. Remove the
3 bezel-to-body screws at the outer circumference of the plastic
bezel. DO NOT remove fuel tank filler tube assembly-to-bezel screws.
Fig. 36: Locating Plastic Bezel & Bezel Screws (Dakota)
Courtesy of Chrysler Corp.
6) Raise and support vehicle. Support fuel tank with
transmission jack. Remove fuel tank strap retaining nuts. Position
fuel tank straps toward outside of vehicle. Slightly lower fuel tank.
If fuel tank was not previously drained, ensure fuel tank cap is
installed to prevent spilling of any fuel.
7) Disconnect fuel line from fuel filter/fuel pressure
Page 984 of 1691
regulator on fuel pump module using proper procedure for fuel line
disconnect fitting. See FUEL LINE DISCONNECT FITTINGS. Fuel pump
module is located on top of fuel tank. See Fig. 27. Disconnect
electrical connector at fuel pump module. Disconnect vapor line from
rollover valve on top of fuel tank.
8) Lower fuel tank from vehicle. If necessary to drain fuel
tank or to remove fuel tank filler tube assembly from fuel tank, go to
next step.
9) Ensure area around disconnect fitting at fuel tank for
fuel tank filler tube assembly is clean. See Fig. 27. The small vent
tube on fuel tank filler tube assembly should be removed first.
CAUTION: Disconnect fitting on small vent tube and large fill tube
must be fully pressed onto fuel tank fitting before pushing
release sleeve into disconnect fitting. Failure to fully
press disconnect fitting fully onto fuel tank fitting will
result in damage to retaining tabs in disconnect fitting.
10) Push disconnect fitting on end of small vent tube toward
fitting fuel tank as far as possible. See Fig. 37. Ensure disconnect
fitting is fully pressed onto fuel tank fitting before attempting to
push release sleeve into disconnect fitting.
11) Push release sleeve upward into disconnect fitting as far
as possible to release the retaining tabs in disconnect fitting. See
Fig. 37 . Ensure release sleeve is pushed evenly into disconnect
fitting. Pull small vent tube with disconnect fitting from fuel tank.
Drain remaining fuel from fuel tank into an approved gasoline
container if necessary.
12) If necessary to remove large fill tube from fuel tank,
push disconnect fitting on end of large fill tube toward fitting fuel
tank as far as possible. See Fig. 37. Ensure disconnect fitting is
fully pressed onto fuel tank fitting before attempting to push release
sleeve into disconnect fitting.
13) Push release sleeve upward into disconnect fitting as far
as possible to release the retaining tabs in disconnect fitting. See
Fig. 37 . Ensure release sleeve is pushed evenly into disconnect
fitting. Pull large fill tube with disconnect fitting from fuel tank.
Fig. 37: Removing & Installing Disconnect Fittings On Fuel Tank
Fitting (Dakota)
Courtesy of Chrysler Corp.
Installation
Page 985 of 1691
1) To install, reverse removal procedure. If installing small
vent tube and large fill tube on fuel tank, ensure fuel tank fittings
are clean.
2) Install disconnect fitting on fuel tank fitting until
disconnect fitting snaps onto fuel tank fitting. Pull on small vent
tube or and large fill tube to ensure disconnect fitting is locked on
fuel tank fitting. To verify proper installation of disconnect
fitting, ensure the distance between release sleeve and top of fuel
tank fitting is .50" (12.7 mm) on small vent tube or .25" (6.4 mm) o\
n
large fill tube. See Fig. 37.
3) Install fuel lines on fuel filter/fuel pressure regulator
on fuel pump module using proper procedure. See FUEL LINE DISCONNECT
FITTINGS under FUEL SYSTEM.
CAUTION: DO NOT overtighten fuel tank strap retaining nuts during
installation.
4) Tighten fuel tank strap retaining nuts to specification.
See TORQUE SPECIFICATIONS. To install remaining components, reverse
removal procedure. Start engine and check for fuel leaks.
Removal (Durango)
1) Fuel tank may be drained by removing vent hose from rear
of fuel tank, or by pumping fuel from fuel tank using the fuel pump if
fuel pump is operating. If removing vent hose from fuel tank to drain
the fuel, go to step 4). If using fuel pump to drain the fuel tank, go
to next step.
2) Disconnect fuel line from fuel rail. See FUEL LINE AT FUEL
RAIL under FUEL SYSTEM. Connect Fuel Hose (6541, 6539, 6631 or 6923)
for proper engine application at fuel line fitting on fuel rail. Place
remaining end of fuel hose in an approved gasoline container.
3) Connect scan tool to Data Link Connector (DLC). DLC is a
16-pin connector attached to bottom of driver's side of the instrument
panel, just to the right of the brake pedal. Using scan tool
manufacturer's instructions, activate the fuel pump and pump fuel from
fuel tank. Once fuel tank is empty, remove scan tool. Reinstall fuel
line on fuel rail using proper procedure. Go to step 5).
4) Release fuel pressure from fuel system. See FUEL SYSTEM
PRESSURE RELEASE. Ensure negative battery cable is disconnected.
Remove fuel tank cap to release any residual fuel tank pressure.
5) Raise and support vehicle. Remove necessary skid plates
for access to fuel tank. Disconnect vent and filler hose from rear of
fuel tank. If fuel tank was not previously drained, place drain hose
in vent hose fitting at rear of fuel tank. Drain fuel from fuel tank
into an approved gasoline container.
6) Support fuel tank with transmission jack. Remove fuel tank
strap retaining nuts. Position fuel tank straps toward outside of
vehicle. Slightly lower fuel tank. Ensure rear of fuel tank is higher
than front of fuel tank to prevent any spilling any remaining fuel in
fuel tank.
7) Disconnect fuel line from fuel filter/fuel pressure
regulator on fuel pump module using proper procedure for fuel line
disconnect fitting. See FUEL LINE DISCONNECT FITTINGS. Fuel pump
module is located on top of fuel tank. See Fig. 28. Disconnect
electrical connector at fuel pump module. Disconnect vapor line from
rollover valves on top of fuel tank and EVAP line from fuel pump
module. Lower fuel tank from vehicle.
CAUTION: DO NOT overtighten fuel tank strap retaining nuts during
installation.
Installation
1) To install, reverse removal procedure. Install fuel lines
Page 990 of 1691
Installation
1) If installing injector on fuel rail, install NEW "O" ring
on injector. Coat "O" ring on injector with engine oil. Install
injector on fuel rail. Position injectors on fuel rails so electrical
connector on injector is facing toward passenger's side of the
vehicle. Install retaining clip on injector and fuel rail.
2) To install remaining components, reverse removal procedure
using NEW "O" ring at bottom of each injector. Coat "O" ring on
injector with engine oil before installing injectors and fuel rails.
3) Push passenger's side fuel rail and then driver's side
fuel rail downward until shoulder on each injector contacts the intake
manifold. Ensure all injectors are fully seated.
4) Tighten fuel rail bolts to specification. See TORQUE
SPECIFICATIONS. Using NEW gasket, install upper intake manifold with
all bolts loosely installed. Tighten upper intake manifold bolts to
specification in sequence. See Fig. 39. See TORQUE SPECIFICATIONS.
5) Tighten throttle body nuts to specification. See TORQUE
SPECIFICATIONS. Install fuel line on fuel rail using proper procedure.
See FUEL LINE AT FUEL RAIL. Start engine and check for leaks.
Fig. 39: Upper Intake Manifold Bolt Tightening Sequence (Ram
Pickup 8.0L)
Courtesy of Chrysler Corp.
THROTTLE BODY
Removal & Installation (Dakota, Durango, Ram Pickup 3.9L,
5.2L & 5.9L, Ram Van & Ram Wagon)
On Ram Van and Ram Wagon, remove engine cover. On all models,
remove air inlet duct or air cleaner from throttle body. Disconnect
electrical connectors, control cables and vacuum hoses at throttle
Page 999 of 1691
SCHEDULED SERVICES - NORMAL SERVICE (DIESEL)
1999 D odge P ic ku p R 1500
1997-99 MAINTENANCE
Chrysler Maintenance & Service Intervals
Diesel Engines
Normal Service
DODGE; RAM PICKUP Cummins Turbo Diesel: 5.9L VIN [D]
* READ THIS FIRST *
Before preforming maintenance on vehicle, ensure that all
cautions and warnings have been observed to prevent vehicle damage or
personal injury. See CAUTIONS & WARNINGS in MAINTENANCE INFORMATION
article in this section.
Introduction
The frequency of scheduled inspection and maintenance
services in this article are based on normal vehicle usage ONLY. The
following Severe conditions are NOT taken into account:
* Frequent short driving less than 5 Miles (8 Km).
* Frequent driving in dusty conditions.
* Frequent trailer towing.
* Extensive idling.
* More than 50% of your driving is at sustained high speeds
during hot weather, above 90
F (32 C).
If the vehicle is operated mainly under any of these
conditions, this Normal service schedule article is inadequate. DO NOT
USE. Instead, use the Severe service schedule: See
SCHEDULED SERVICES - NORMAL SERVICE (DIESEL) .
6,000 MILE (10,000 KM)/6 MONTH NORMAL SERVICE
6,000 MILE (10,000 KM)/6 MONTH NORMAL SERVICE\
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Exhaust System
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Brake Hoses
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Engine Coolant Level, Hoses & Clamps
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SERVICE
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Rotate Tires
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Lubricate Steering Linkage
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REPLACE
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Engine Oil
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LUBRICATION SPECIFICATIONS
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Material Condition Specification
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Page 1029 of 1691
SC HED ULE D S ER VIC ES - N O RM AL S ER VIC E ( G AS)
1 999 D odge P ic ku p R 1500
1997-99 MAINTENANCE
Chrysler Maintenance & Service Intervals
Gasoline Engines
Normal Service/Light Duty Trucks
DODGE; RAM PICKUP 1500: 3.9L VIN [X]
DODGE; RAM PICKUP 1500/2500: 5.2L VIN [Y]
DODGE; RAM PICKUP 1500/2500: 5.2L VIN [T]
DODGE; RAM PICKUP 1500/2500: 5.9L VIN [Z]
* READ THIS FIRST *
Before preforming maintenance on vehicle, ensure that all
cautions and warnings have been observed to prevent vehicle damage or
personal injury. See CAUTIONS & WARNINGS in MAINTENANCE INFORMATION
article in this section.
Introduction
The frequency of scheduled inspection and maintenance
services in this article are based on normal vehicle usage ONLY. The
following Severe conditions are NOT taken into account:
* Frequent short driving less than 5 Miles (8 Km).
* Frequent driving in dusty conditions.
* Frequent trailer towing.
* Extensive idling.
* More than 50% of your driving is at sustained high speeds
during hot weather, above 90
F (32 C).
If the vehicle is operated mainly under any of these
conditions, this Normal service schedule article is inadequate. DO NOT
USE. Instead, use the Severe service schedule: See
SCHEDULED SERVICES - SEVERE SERVICE (GAS) .
7,500 MILE (12,000 KM)/6 MONTH NORMAL SERVICE
7,500 MILE (12,000 KM)/6 MONTH NORMAL SERVICE\
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SERVICE
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Rotate Tires
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Lubricate Steering Linkage
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REPLACE
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1) - If mileage is less than 7,500 miles (12,000 KM) yearly,
replace the oil filter at every oil change.
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Page 1054 of 1691
SC HED ULE D S ER VIC ES - S EVER E S ER VIC E ( D IE SEL)
1 999 D odge P ic ku p R 1500
1997-99 MAINTENANCE
Chrysler Maintenance & Service Intervals
Diesel Engines
Severe Service
DODGE; RAM PICKUP Cummins Turbo Diesel: 5.9L VIN [D]
* READ THIS FIRST *
Before preforming maintenance on vehicle, ensure that all
cautions and warnings have been observed to prevent vehicle damage or
personal injury. See CAUTIONS & WARNINGS in MAINTENANCE INFORMATION
article in this section.
Introduction
The frequency of scheduled inspection and maintenance
services in this article are based on Severe Duty vehicle usage ONLY.
Severe Duty vehicle usage is defined as any one of the following
conditions:
* Frequent short driving less than 5 Miles (8 16 Km).
* Frequent driving in dusty conditions.
* Frequent trailer towing.
* Extensive idling.
* More than 50% of your driving is at sustained high speeds
during hot weather, above 90
F (32 C).
If none of these conditions apply, this Severe service
schedule article is excessive. DO NOT USE. Instead, use the Normal
service schedule: See SCHEDULED SERVICES - NORMAL SERVICE (DIESEL) .
3,000 MILE (5,000 KM) SEVERE DUTY SERVICE
3,000 MILE (5,000 KM) SEVERE DUTY SERVICE\
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SERVICE
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Lubricate Steering Linkage
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REPLACE
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Engine Oil
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Engine Oil Filter
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LUBRICATION SPECIFICATIONS
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Engine Oil Ambient Temperature Above 10 F SAE 15W-40
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1) (-12 C) To Over 30 F (-1 C)
Page 1114 of 1691
SC HED ULE D S ER VIC ES - S EVER E S ER VIC E ( G AS)
1 999 D odge P ic ku p R 1500
1997-99 MAINTENANCE
Chrysler Maintenance & Service Intervals
Gasoline Engines
Severe Service/Light Duty Trucks
DODGE; RAM PICKUP 1500: 3.9L VIN [X]
DODGE; RAM PICKUP 1500/2500: 5.2L VIN [Y]
DODGE; RAM PICKUP 1500/2500: 5.2L VIN [T]
DODGE; RAM PICKUP 1500/2500: 5.9L VIN [Z]
* READ THIS FIRST *
Before preforming maintenance on vehicle, ensure that all
cautions and warnings have been observed to prevent vehicle damage or
personal injury. See CAUTIONS & WARNINGS in MAINTENANCE INFORMATION
article in this section.
Introduction
The frequency of scheduled inspection and maintenance
services in this article are based on Severe Duty vehicle usage ONLY.
Severe Duty vehicle usage is defined as any one of the following
conditions:
* Frequent short driving less than 5 Miles (8 16 Km).
* Frequent driving in dusty conditions.
* Frequent trailer towing.
* Extensive idling.
* More than 50% of your driving is at sustained high speeds
during hot weather, above 90
F (32 C).
If none of these conditions apply, this Severe service
schedule article is excessive. DO NOT USE. Instead, use the Normal
service schedule: See appropriate
SCHEDULED SERVICE - NORMAL SERVICE (GAS) article.
3,000 MILE (5,000 KM) SEVERE DUTY SERVICE
3,000 MILE (5,000 KM) SEVERE DUTY SERVICE\
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Exhaust System
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Brake Hoses
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Engine Coolant Level, Hoses & Clamps
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SERVICE
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Rotate Tires
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Lubricate Steering Linkage
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REPLACE
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Engine Oil
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Engine Oil Filter (
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