Fuel pump DODGE RAM 1999 Service Service Manual

gear. When installing pump, ensure dowel on mounting flange must align
with hole in front of pump. Ensure fuel injection pump is flat against
gear housing. Install 4 fuel injection pump-to-gear housing nuts
finger tight. DO NOT tighten nuts at this time.
CAUTION: DO NOT tighten pump to gear cover using mounting nuts. Damage
to pump or gear cover may result. Pump must be positioned
flat to mounting flange before attempting to tighten mounting
nuts.
4) Install fuel injection pump shaft washer and nut to pump
shaft finger tight. Position lower pump bracket and install 3 bolts
finger tight. Tighten fuel injection pump drive gear nut to
preliminary torque of 22 ft. lbs. (30 N.m). Tighten 4 fuel injection
pump nuts and 3 lower pump bracket-to-pump bolts to specification.
Tighten 2 engine bracket-to-engine bolts to specification. See TORQUE
SPECIFICATIONS Final tighten injection pump shaft nut. Use barring
tool to prevent engine from rotating.
5) Install plastic access cap to front gear cover. Using new
gaskets, install fuel return line and overflow valve to side of
injection pump. Tighten overflow valve to specification. See TORQUE
SPECIFICATIONS Using new gaskets, install fuel supply line to side of
injection pump and top of fuel filter housing. Tighten banjo bolts to
specification. TORQUE SPECIFICATIONS.
6) To complete installation, reverse removal procedure. Bleed
air from fuel system. See FUEL LINE BLEEDING.
FUEL TANK ROLLOVER VALVE
Removal
1) Fuel tank rollover valve is pressed into rubber grommet on
top of fuel tank module. See Fig. 7. Manufacturer recommends removing
fuel tank for access to fuel tank rollover valve.
NOTE: It may be necessary to disconnect fuel lines and electrical
connector from fuel tank module so fuel tank may be lowered
for access to fuel tank rollover valve.
2) Raise and support vehicle. Disconnect negative battery
cables. Drain fuel tank. Remove fuel tank filler tube bolts from body.
Support fuel tank with transmission jack. Remove fuel tank straps and
heat shields (if equipped).
NOTE: Manufacturer recommends replacing rubber grommet on fuel tank
module when servicing fuel tank rollover valve.
3) Slightly lower fuel tank for access to fuel tank rollover
valve. Disconnect electrical connector and fuel lines from fuel tank
module if necessary to gain access to fuel tank rollover valve. Use
proper procedure when disconnecting fuel lines. See FUEL LINE
DISCONNECT FITTINGS under FUEL SYSTEM.
4) Disconnect hose from fuel tank rollover valve. Pry one
side of fuel tank rollover valve from rubber grommet. Remove fuel tank
rollover valve. Remove rubber grommet.
Installation
1) To install, reverse removal procedure using NEW rubber
grommet. If fuel lines were disconnected, install fuel lines on fuel
tank module using proper procedure. See FUEL LINE DISCONNECT FITTINGS
under FUEL SYSTEM.
2) Reinstall fuel tank. Tighten fuel tank strap nuts to
specification. See TORQUE SPECIFICATIONS. Reconnect negative battery
cables.

FUEL TRANSFER PUMP
Removal
1) Disconnect negative battery cables. Clean area around
transfer pump and fuel lines. Remove starter. Place a drain pan below
pump. Disconnect fuel line fitting at fuel supply line. Remove support
bracket bolt at top of pump. Remove banjo bolts at front and rear of
pump.
2) Disconnect pigtail harness electrical connector from main
engine wiring harness. Remove 3 pump bracket nuts. Remove fuel
transfer pump.
Installation
1) Install new gaskets to fuel supply line, support bracket,
and banjo bolt at rear of pump. Install banjo bolt finger tight.
Install new gaskets to fuel line and banjo bolt at front of pump.
Position 3 pump studs into pump mounting bracket and install 3 nuts
finger tight. Install support bracket bolt finger tight.
2) Tighten bolts and nuts evenly to specification. See TORQUE
SPECIFICATIONS. Reconnect electrical connectors. Tighten fuel lines to
specification. Install starter and negative battery cables. Bleed low-
pressure fuel lines. See FUEL LINE BLEEDING under FUEL SYSTEM.
HIGH-PRESSURE FUEL LINES
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. Remove nameplate
located above rocker lever covers. Disconnect necessary clamps from
high-pressure fuel lines.
2) Ensure area around each high-pressure fuel line nut is
clean. Mark high-pressure fuel line location for installation
reference. Remove high-pressure fuel line from fuel injector.
3) Remove high-pressure fuel lines from fuel injection pump.
Remove high-pressure fuel lines from engine, using care not to bend
the fuel line.
Installation
To install, reverse removal procedure. Ensure all high-
pressure fuel line nuts are tightened to specification at fuel
injector and fuel injection pump before tightening clamp bolts to
specification. Bleed high-pressure fuel lines. See FUEL LINE BLEEDING
under FUEL SYSTEM.
OVERFLOW VALVE
Removal & Installation
1) Disconnect negative battery cables. Ensure area around
overflow valve is clean. Remove valve from pump and banjo fitting.
Discard gaskets.
2) To install, reverse removal procedure using NEW gaskets.
Tighten overflow valve to specification. See TORQUE SPECIFICATIONS.
EMISSION SYSTEMS & SUB-SYSTEMS

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








\









\









\









\









\









\









\







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.









\









\









\









\









\









\









\

TRANSMISSION TEMPERATURE SENSOR
Removal & Installation (A/T Models)
Transmission temperature sensor is located on transmission
valve body, incorporated into governor pressure sensor. See
appropriate ELECTRONIC CONTROLS article in AUTOMATIC TRANSMISSIONS
section.
UPSTREAM OXYGEN SENSOR
NOTE: Upstream oxygen sensor may also be referred to as pre
-catalyst oxygen sensor.
Removal
Upstream oxygen sensor is mounted on exhaust pipe, in front
of catalytic converter. Raise and support vehicle. Disconnect
electrical connector for upstream oxygen sensor. Using Socket
(YA8875), remove upstream oxygen sensor from exhaust pipe.
Installation
1) If installing original or used upstream oxygen sensor,
apply anti-seize compound on threads of upstream oxygen sensor. A NEW
upstream oxygen sensor should already be coated with anti-seize
compound.
2) Install and tighten upstream oxygen sensor to
specification. See TORQUE SPECIFICATIONS. Install electrical
connector.
MOTORS, RELAYS & SOLENOIDS
IDLE AIR CONTROL (IAC) MOTOR
Removal & Installation (Dakota, Durango, Ram Pickup 3.9L,
5.2L & 5.9L, Ram Van & Ram Wagon)
1) IAC motor is located on throttle body and contains a 4-pin
electrical connector. On Ram Van and Ram Wagon, remove engine cover.
2) On all models, remove air inlet duct or air cleaner
assembly for access to IAC motor. Disconnect electrical connector at
IAC motor. Remove retaining bolts and IAC motor from throttle body.
3) To install, reverse removal procedure. Tighten IAC motor
retaining bolts to specification. See TORQUE SPECIFICATIONS.
Removal & Installation (Ram Pickup 8.0L)
1) IAC motor is located at rear of throttle body and contains
a 4-pin electrical connector. Remove air inlet duct at air cleaner
assembly. Remove cover from air cleaner assembly.
2) Remove air cleaner housing-to-throttle body nuts and air
cleaner housing from throttle body. Disconnect electrical connector at
IAC motor. Remove retaining bolts and IAC motor.
3) To install, reverse removal procedure. Tighten IAC motor
retaining bolts and air cleaner housing-to-throttle body nuts to
specification. See TORQUE SPECIFICATIONS.
A/C RELAY, AUTO SHUTDOWN (ASD) RELAY & FUEL PUMP RELAY
NOTE: A/C relay may also be referred to as A/C clutch relay or A/C
compressor clutch relay.
Removal & Installation
Relays are located in Power Distribution Center (PDC). Relays\
may be identified by label on inside of PDC cover. See POWER
DISTRIBUTION CENTER (PDC) LOCATION table.

Installation
1) If engine has not been rotated after removing distributor,
go to next step. If engine was rotated after removing distributor,
rotate crankshaft clockwise (viewed from front of engine) until
cylinder No. 1 is at Top Dead Center (TDC) on compression stroke and
timing mark on vibration damper aligns with TDC timing mark on timing
chain cover. Go to next step.
2) Ensure distributor mounting area on cylinder block is
clean. Install NEW "O" ring on distributor if necessary. Apply light
coat of engine oil on "O" ring.
3) Position distributor rotor so it aligns with terminal for
cylinder No. 1 on distributor cap. Install distributor. Ensure
distributor engages with slot in oil pump drive gear. Install hold-
down clamp and distributor hold-down bolt. DO NOT tighten distributor
hold-down bolt at this time.
4) Rotate distributor until distributor rotor aligns with
cylinder No. 1 alignment mark on camshaft position sensor. See Fig. 23
. Tighten distributor hold-down bolt to specification. See TORQUE
SPECIFICATIONS. To install remaining components, reverse removal
procedure.
5) Base ignition timing is nonadjustable. Base ignition
timing and timing advance are controlled by the Powertrain Control
Module (PCM). Distributor position is used to determine the fuel
system synchronization. To check for correct distributor position and
fuel system synchronization, see FUEL SYSTEM SYNCHRONIZATION under
FUEL SYSTEM in ON-VEHICLE ADJUSTMENTS article.
IGNITION COIL
Removal & Installation (Dakota 2.5L)
Ignition coil is located on side of engine, near distributor.
Service procedure is primarily an unbolt and bolt-on procedure.
Tighten ignition coil retaining bolts or nuts to specification. See
TORQUE SPECIFICATIONS.
Removal & Installation (Dakota 3.9L, 5.2L & 5.9L, Durango &
Ram Van/Wagon)
1) Ignition coil is located on front of passenger's side
cylinder head. Disconnect spark plug wires and electrical connector
from ignition coil.
CAUTION: Ignition coil-to-cylinder head mounting bracket bolts hold
the idler pulley for the accessory drive belt, as these bolts
are under tension. If necessary to remove these bolts,
accessory drive belt must be removed first.
2) Remove ignition coil retaining bolts or nuts with ignition
coil from the ignition coil mounting bracket. DO NOT remove ignition
coil-to-cylinder head mounting bracket bolts, as these bolts are under
tension.
3) To install, reverse removal procedure. Tighten ignition
coil retaining bolts or nuts to specification. See TORQUE
SPECIFICATIONS.
Removal & Installation (Ram Pickup 3.9L, 5.2L & 5.9L)
1) On 3.9L, 5.2L and 5.9L with light-duty emissions, ignition
coil is located on front of passenger's side cylinder head. On 5.9L
with heavy-duty emissions, ignition coil is located on top of air
injection pump. On all models, disconnect spark plug wires and
electrical connector from ignition coil.
CAUTION: On 3.9L, 5.2L and 5.9L with light-duty emissions, ignition
coil-to-cylinder head mounting bracket bolts hold the idler

pulley for the accessory drive belt, as these bolts are under
tension. If necessary to remove these bolts, accessory drive
belt must be removed first.
2) Remove ignition coil retaining bolts or nuts with ignition
coil from the ignition coil mounting bracket. On 3.9L, 5.2L and 5.9L
with light-duty emissions, DO NOT remove ignition coil-to-cylinder
head mounting bracket bolts, as these bolts are under tension. On all
applications, to install, reverse removal procedure. Tighten ignition
coil retaining bolts or nuts to specification. See TORQUE
SPECIFICATIONS.
Removal & Installation (Ram Pickup 8.0L)
1) Two separate ignition coils are located above passenger's
side valve cover. Each ignition coil can be serviced separately. On
all ignition coil applications, disconnect spark plug wires and
electrical connector from ignition coil.
2) Remove ignition coil retaining bolts and ignition coil
from ignition coil mounting bracket. To install, reverse removal
procedure. Ensure ignition coil is mounted on ignition coil mounting
bracket with electrical connector facing downward. Tighten ignition
coil retaining bolts to specification. See TORQUE SPECIFICATIONS.
FUEL SYSTEM
FUEL SYSTEM PRESSURE RELEASE
WARNING: Always release fuel pressure before disconnecting any fuel
injection-related component. DO NOT allow fuel to contact
engine or electrical components.
1) Remove fuel cap from fuel tank. Note location of spring
loaded flapper valve inside fuel tank filler tube assembly. Flapper
valve is located just below the fuel cap area on fuel tank filler tube
assembly. Flapper valve is used as a secondary way of sealing the fuel
tank if fuel cap was not properly tightened.
WARNING: When opening flapper valve inside fuel tank filler tube
assembly, ensure a non-metallic object is used to prevent any
sparks.
2) Using a non-metallic object, push flapper valve inside
filler tube assembly downward to release any pressure from the fuel
tank. Ensure all pressure is released from fuel tank.
3) Remove fuel pump relay from Power Distribution Center
(PDC). Fuel pump relay may be identified by label on inside of PDC
cover. See POWER DISTRIBUTION CENTER (PDC) LOCATION table.
4) On all models, start engine and allow engine to idle until
engine stalls. Attempt to restart engine until engine will no longer
run. Turn ignition off.
CAUTION: Ensure steps 1) through 4) are performed before proceeding.
Steps 3) and 4) must be performed to ensure most of the fuel
pressure is released from fuel rails to prevent an excessive
amount of fuel being delivered into the cylinders.
5) Remaining fuel pressure is released by energizing a fuel
injector. Disconnect electrical connector at any fuel injector.
6) Connect jumper wire between one electrical terminal on
fuel injector and positive battery terminal. Connect another jumper
wire on remaining electrical terminal on fuel injector.

CAUTION: DO NOT apply battery voltage to fuel injector for extended
periods, or fuel injector may be damaged.
7) Momentarily touch remaining end of jumper wire to negative
battery terminal in short intervals to energize fuel injector and
release remaining fuel pressure.
8) Remove jumper wires. Reinstall electrical connector and
fuel pump relay. Fuel system components may now be serviced. Cover
fuel lines with shop towel before disconnecting, as some residual fuel
pressure may exist.
9) Diagnostic Trouble Code (DTCs) may have been stored in
Powertrain Control Module (PCM) due to the removal of fuel pump relay.\
Using scan tool, clear DTCs from PCM. See appropriate SELF-DIAGNOSTICS
article for clearing of DTCs.
FUEL LINE DISCONNECT FITTINGS
NOTE: Fuel lines may contain single tab, dual tab or plastic
retainer ring disconnect fitting. See Fig. 24. Determine type
of disconnect fitting used and use proper procedure for
proper disconnect fitting.
Fig. 24: Identifying Fuel Line Disconnect Fitting
Courtesy of Chrysler Corp.
Removal & Installation (Single Tab)
1) Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE

1) Fuel filter/fuel pressure regulator is mounted in rubber
grommet on top of fuel pump module. See Figs. 27-30. Fuel pump module
is located on top of fuel tank.
2) Manufacturer recommends removing fuel tank for access to
fuel filter/fuel pressure regulator. See FUEL TANK. Ensure area around
fuel filter/fuel pressure regulator and fuel pump module is clean.
CAUTION: When removing fuel filter/fuel pressure regulator from fuel
tank, DO NOT pull fuel filter/fuel pressure regulator more
than 3.0" (76 mm) from fuel tank or plastic fuel line
attached to fuel filter/fuel pressure regulator may be
damaged.
3) Using twisting motion, pull fuel filter/fuel pressure
regulator from rubber grommet on fuel pump module. Ensure fuel
filter/fuel pressure regulator is not pulled more than 3.0" (76 mm)
from fuel tank or plastic fuel line attached to fuel filter/fuel
pressure regulator may be damaged.
4) Carefully cut plastic fuel line-to-fuel filter/fuel
pressure regulator retaining clamp. Use care not to damage plastic
fuel line. Remove retaining clamp. Remove plastic fuel line from fuel
filter/fuel pressure regulator.
Installation
1) Install plastic fuel line with NEW retaining clamp on fuel
filter/fuel pressure regulator. Rotate fuel filter/fuel pressure
regulator in plastic fuel line until fuel line fitting on side fuel
filter/fuel pressure regulator points proper direction. See
POSITIONING FUEL FILTER/FUEL PRESSURE REGULATOR table.
POSITIONING FUEL FILTER/FUEL PRESSURE REGULATOR









\









\









\









\









\









\









\







Application Location Of Fuel Line Fitting
Dakota ............................. Toward Driver's Side Of Vehicle
Durango .................................... Toward Front Of Vehicle
Ram Pickup, Ram Van & Ram Wagon .... Toward Driver's Side Of Vehicle









\









\









\









\









\









\









\







CAUTION: Ensure Crimping Pliers (C-4124) are used to crimp retaining
clamp for plastic fuel line. DO NOT use conventional side
cutters to crimp retaining clamp.
2) Using Crimping Pliers (C-4124), crimp retaining clamp for\
plastic fuel line. Ensure plastic fuel line is securely attached on
fuel filter/fuel pressure regulator.
3) To install remaining components, reverse removal
procedure. Ensure fuel filter/pressure regulator is installed in
rubber grommet on fuel pump module so fuel line fitting on side fuel
filter/fuel pressure regulator points toward proper direction before
installing fuel tank. See POSITIONING FUEL FILTER/FUEL PRESSURE
REGULATOR table. Reinstall fuel tank using proper procedure.

Fig. 27: Locating Fuel Pump Module & Components (Dakota)
Courtesy of Chrysler Corp.
Fig. 28: Locating Fuel Pump Module & Components (Durango)
Courtesy of Chrysler Corp.

Fig. 29: Locating Fuel Pump Module & Components (Ram Pickup)
Courtesy of Chrysler Corp.
Fig. 30: Locating Fuel Pump Module & Components (Ram Van & Ram Wagon)\
Courtesy of Chrysler Corp.
FUEL LEVEL SENSOR