Fuel lines DODGE RAM 1999 Service User Guide

1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect negative battery cable. Drain cooling system. Disconnect
accelerator, cruise control, and transmission kickdown cables.
Disconnect fuel lines at throttle body. See FUEL LINE DISCONNECT
FITTINGS.
2) Remove engine cover (Ram Van/Wagon), air cleaner and
generator. Disconnect necessary electrical wiring, coolant hoses and
vacuum hoses. Remove distributor cap and spark plug wires. Remove
valve covers (if necessary).
3) Remove bolts, intake manifold and gaskets. Separate
throttle body from intake manifold (if necessary). Turn intake
manifold upside-down and remove plenum pan (if necessary).
Fig. 4: Plenum Pan Bolt Tightening Sequence
Courtesy of Chrysler Corp.
Installation
1) Install plenum pan and install all bolts finger tight.

and camshaft. To install remaining components, reverse removal
procedure.
Fig. 8: Aligning Timing Marks
Courtesy of Chrysler Corp.
ROCKER ARMS
Removal
Disconnect spark plug wires, PCV and fuel evaporation hoses.
Remove valve covers. Remove bolts, pivots, and rocker arms. Wire
components together for installation reference. Mark each push rod for
location, and remove (if necessary).
CAUTION: To avoid piston-to-valve contact during rocker arm
installation, crankshaft must be placed in specified
position. Wait 5 minutes before starting engine to allow
valve lifters to bleed down after rocker arm installation.
Installation
1) On 3.9L engine, locate "V6" mark stamped on vibration
damper (147 degrees ATDC). Rotate engine by hand until "V6" mark lines\
up with TDC mark on timing chain cover.
2) On 5.2L and 5.9L engines, locate "V8" mark stamped on
vibration damper (147 degrees ATDC). Rotate engine by hand until "V8"
mark lines up with TDC mark on timing chain cover.
3) Install rocker arm and pivot assemblies and tighten bolt
to 21 ft. lbs. (28 N.m). Wait 5 minutes before starting engine to
allow valve lifters to bleed down after rocker arm installation. To
install remaining components, reverse removal procedure. Tighten valve
cover bolts to 95 INCH lbs. (11 N.m).
VALVE LIFTERS

FUEL TANKS
GAS CAPS
GASKETS
GROMMETS (VALVE COVER)
HARMONIC DAMPERS
HEATER CONTROL VALVES
HEATER CORES
HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS
HOSE CLAMPS
HOSE CONNECTORS
HOSE COUPLERS
HOSES AND TUBES (FUEL LINES, RADIATOR, VACUUM, BY PASS,
HEATER, RECOVERY TANK AND OIL COOLERS)
HOUSINGS
IDLE AIR CONTROLS
IDLE SPEED CONTROL ACTUATORS
IGNITION BOOTS
IGNITION COIL TOWERS
IGNITION COILS
IGNITION CONTROL MODULES (ICM)
IGNITION SWITCHES
IGNITION TERMINALS
IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY)
IN-TANK FUEL STRAINERS
INERTIA FUEL SHUT-OFF SWITCHES
INTAKE AIR TEMPERATURE SENSORS
INTAKE MANIFOLDS
INTERCOOLERS
KNOCK SENSORS
LIQUID VAPOR SEPARATORS
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORS
MASS AIR FLOW (MAF) SENSORS
METAL AIR MANIFOLDS AND PIPES
METAL AIR PIPES
MIX CONTROL SOLENOIDS
MOTOR MOUNTS
O-RINGS, GASKETS, SEALS AND SPRING LOCKS
O2 SENSORS
OIL PRESSURE SENDING UNITS
OIL PUMP PICK-UP SCREENS
OIL PUMPS
PARK NEUTRAL POSITION SWITCHES
PCV BREATHER ELEMENTS
PCV ORIFICES
PCV VALVES
PICK-UP ASSEMBLIES (INCLUDES MAGNETIC, HALL EFFECT AND
OPTICAL)
POWER STEERING PRESSURE SENSORS
POWERTRAIN CONTROL MODULES (PCM) AND PROM
POWERTRAIN CONTROL PROM
PRESSURIZED EXPANSION TANK CAPS
RADIATOR CAPS AND PRESSURIZED EXPANSION TANK CAPS
RADIATOR FAN BLADES
RADIATOR FAN CLUTCHES
RADIATORS
ROLL OVER VALVES
SEALING COMPOUNDS
SEALS
SECONDARY AIR INJECTION SYSTEM MANAGEMENT DEVICES
SENSORS AND ACTUATORS
SHROUDS, BAFFLES AND DEFLECTORS
SPARK PLUGS
SPRING LOCKS

affecting performance .. A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.









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HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS
NOTE: When replacing fuel lines and hoses, replace with product
that meets or exceeds OEM design specifications.
HOSE AND TUBE COUPLER, CONNECTOR AND CLAMP INSPECTION









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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Connected incorrectly ... A ................. Require repair.
Corroded, not reusable .. 1 ............ Suggest replacement.
Cracked ................. A ............ Require replacement.
Insufficient clamping
force, allowing hose to
leak ................... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Safety clip missing (not
leaking) ............... C ... Require replacement of safety
clip.
Stripped ................ A ............ Require replacement.









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HOSE CLAMPS
See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .
HOSE CONNECTORS
See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .
HOSE COUPLERS
See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .
HOSES AND TUBES (FUEL LINES, RADIATOR, VACUUM, BY PASS,
HEATER, RECOVERY TANK AND OIL COOLERS)
HOSE AND TUBE (FUEL LINE, RADIATOR, VACUUM, BY PASS, HEATER,
RECOVERY TANK AND OIL COOLER) INSPECTION









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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Connected incorrectly ... A ................. Require repair.
Corroded, not reusable .. 1 ............ Suggest replacement.
Cracked ................. A ............ Require replacement.
Dry-rotted .............. 1 .. Suggest repair or replacement.
Hard .................... 1 .. Suggest repair or replacement.
Inner fabric (webbing)
damaged ................ A ............ Require replacement.
Insufficient clamping
force, allowing hose to
leak ................... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Maintenance intervals ... 3 ............ Suggest replacement.

check for accepted cleaning procedure.








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TUBE CLAMPS
See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .
TUBE CONNECTORS
See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .
TUBE COUPLERS
See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .
TUBES
See HOSES AND TUBES (FUEL LINES , RADIATOR, BY PASS, HEATER,
RECOVERY TANK AND OIL COOLERS).
TURBO CHARGERS
TURBO CHARGER 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.
Boost pressure
incorrect .............. A ........... ( 1) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Oil seal (internal)
leaking ................ A .. Require repair or replacement.
Vibrates ................ A .. Require repair or replacement.
( 1) - Boost pressure problems may be caused by other systems
or components.









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VACUUM CONNECTIONS
See VACUUM HOSES, TUBES AND CONNECTIONS (NON-METALLIC) .
VACUUM HOSES, TUBES AND CONNECTIONS (NON-METALLIC)
VACUUM HOSE, TUBE AND CONNECTION (NON-METALLIC) INSPECTION








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Condition Code Procedure
Leaking ................. A .. Require repair or replacement.
Melted .................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Oil-soaked (spongy) ..... 1 ............ Suggest replacement.

Fig. 6: Hand Priming Diesel Engine (Out of Fuel)
Courtesy of Chrysler Corp.
NOTE: For more information regarding 5.9L Diesel engine service
refer to the 5.9L V8 TURBO DIESEL - VIN [D] article
in the ENGINE MECHANICAL section.
When a diesel vehicle runs out of fuel, air is pulled into
the fuel lines and prevents fuel from reaching engine. To
restart perform the following:

1). Add 5 to 10 gallons of fuel to vehicle tank.
2). Open the hood and hand operate the fuel lift pump by
pushing down on prime button until resistance is felt
(approximately 30 times).
3). Start engine using normal procedure.
4). Engine may run rough until air is forced from lines.
CAUTION: If this procedure fails to start vehicle, more involved
procedures may be required.
Fig. 7: Valve Adjustment - Timing Pin Location (Diesel)
Courtesy of Chrysler Corp.
NOTE: For more information regarding 5.9L Diesel engine service
refer to the 5.9L V8 TURBO DIESEL - VIN [D]

FUEL LINE DISCONNECT FITTINGS
NOTE: Fuel lines may contain single tab, dual tab or plastic
retainer ring disconnect fitting. See Fig. 6. Determine type
of disconnect fitting used and use proper procedure for
proper disconnect fitting.
Fig. 6: Identifying Fuel Line Disconnect Fitting
Courtesy of Chrysler Corp.
Removal & Installation (Single Tab)
1) Disconnect negative battery cables. Ensure disconnect

fitting and fuel lines are clean. Note location of release tab and
pull tab on disconnect fitting. See Fig. 6.
CAUTION: Release tab must be pressed downward before removing pull tab
or pull tab will be damaged.
2) Press release tab downward. Use screwdriver to pry pull
tab upward until pull tab separates from disconnect fitting. Remove
disconnect fitting from fuel line. Inspect components for damage. If
disconnect fitting is damaged, entire assembly must be replaced, as
only pull tab can be replaced.
3) To install, ensure fuel line and disconnect fitting are
clean. Lubricate fuel line and disconnect fitting with engine oil.
Install disconnect fitting on fuel line until disconnect fitting
bottoms on fuel line.
4) Install NEW pull tab until pull tab locks in disconnect
fitting. DO NOT reuse old pull tab. Pull on fuel line and disconnect
fitting to ensure components are properly locked together. Reconnect
negative battery cables. Start engine and check for leaks.
Removal & Installation (Dual Tab)
1) Disconnect negative battery cables. Ensure disconnect
fitting and fuel lines are clean. Note location of tabs on disconnect
fitting. See Fig. 6.
2) Squeeze both tabs against disconnect fitting. Pull
disconnect fitting from fuel line. The plastic retainer will remain on
the fuel system component being serviced. The "O" rings and spacer
will remain in the disconnect fitting.
3) Inspect components for damage. If disconnect fitting is
damaged, entire assembly must be replaced. The only component that may
be replaced is the plastic retainer. If plastic retainer must be
removed from fuel system component, carefully release the plastic
retainer from the fuel system component using 2 screwdrivers. Inspect
plastic retainer for cracks or damage. Replace plastic retainer if
defective.
4) To install, ensure fuel line and disconnect fitting are
clean. Lubricate fuel line and disconnect fitting with engine oil.
Install disconnect fitting on fuel line until click sound is heard.
5) Pull on fuel line and disconnect fitting to ensure
components are properly locked together. Reconnect negative battery
cables. Start engine and check for leaks.
Removal & Installation (Plastic Retainer Ring)
1) Disconnect negative battery cables. Ensure disconnect
fitting and fuel lines are clean. Note location of plastic retainer
ring on disconnect fitting. See Fig. 6.
NOTE: Plastic retainer ring must be pressed evenly into disconnect
fitting. If plastic retainer is not even, it will be
difficult to remove disconnect fitting from fuel line.
2) Firmly push disconnect fitting toward the fuel line while
pushing plastic retainer ring evenly into disconnect fitting. With
plastic retainer ring fully depressed, pull disconnect fitting from
fuel line.
3) Inspect components for damage. If disconnect fitting is
damaged, entire assembly must be replaced.
4) To install, ensure fuel line and disconnect fitting are
clean. Lubricate fuel line and disconnect fitting with engine oil.
Install disconnect fitting on fuel line until click sound is heard.
5) Pull on fuel line and disconnect fitting to ensure
components are properly locked together. Reconnect negative battery
cables. Start engine and check for leaks.

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.