tow DODGE RAM 1999 Service Manual Online
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 937 of 1691
injection pump timing, cylinder No. 1 at TDC on compression
stroke and timing pin is engaged in machined hole on camshaft
gear.
Installation
1) Check pump mounting surfaces at pump and mounting flange
for nicks, cuts or damage. Check "O" ring surfaces for nicks, cuts or
damage. Clean injection pump mounting flange at gear housing. Clean
front of injection pump. Install new "O" ring on pump mounting area.
Apply clean engine oil to injection pump "O" ring only.
CAUTION: Ensure fuel injection pump drive gear-to-shaft mating
surfaces are clean and free of oil to provide proper seating
of fuel injection pump drive gear on shaft of fuel injection
pump.
2) Pump/gear keyway has an arrow and 3-digit number stamped
at top edge. See Fig. 12. Position keyway into pump shaft with arrow
pointed toward rear of pump. Ensure 3-digit number stamped on top of
keyway is identical as 3-digit number stamped on injection pump data
plate. If incorrect keyway is installed, a Diagnostic Trouble Code
(DTC) may be set.
Fig. 12: Locating Keyway Arrow & Keyway Number
Courtesy of Chrysler Corp.
3) Position pump assembly to mounting flange on gear cover
while aligning injection pump shaft through back of injection pump
Page 945 of 1691
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.
Page 959 of 1691
![DODGE RAM 1999 Service Manual Online distance is about 2.018" (51.26 mm), rotate engine by using crankshaft\
vibration damper retaining bolt until distance from the surface at
camshaft position sensor mounting hole opening on timing cha](/img/12/56915/w960_56915-958.png "DODGE RAM 1999 Service Manual Online distance is about 2.018\" (51.26 mm), rotate engine by using crankshaft\
vibration damper retaining bolt until distance from the surface at
camshaft position sensor mounting hole opening on timing cha")
distance is about 2.018" (51.26 mm), rotate engine by using crankshaft\
vibration damper retaining bolt until distance from the surface at
camshaft position sensor mounting hole opening on timing chain cover
to the camshaft sprocket is about 1.818" (46.18 mm). This will put the\
high machined area on camshaft sprocket toward the camshaft position
sensor. Go to next step.
CAUTION: Ensure proper measurement is obtained before installing
camshaft position sensor. DO NOT install camshaft position
sensor with low machined area on camshaft sprocket aligned
with camshaft position sensor mounting hole opening on timing
chain cover, or camshaft shaft position sensor will be
damaged when engine is started.
3) Using a slight rocking action, lightly push camshaft
position sensor into timing chain cover until rib material at camshaft
end of camshaft position sensor contacts camshaft sprocket. DO NOT
twist camshaft position sensor during installation or "O" ring may be
damaged.
4) Install and tighten camshaft position sensor retaining
bolt to specification. See TORQUE SPECIFICATIONS. Reinstall electrical
connector on camshaft position sensor. When engine is started, rib
material at camshaft end of camshaft position sensor will be sheared
off and the air gap will be automatically set.
Installation (Original Or Used Camshaft Position Sensor)
1) Camshaft position sensor installation depth must be
adjusted to prevent camshaft position sensor from contacting the
camshaft sprocket. Inspect camshaft end of camshaft position sensor to
see if any of the original rib material is still present. See Fig. 16.
The rib material was used to position the camshaft position sensor at
the correct installation depth when the sensor was originally
installed.
CAUTION: DO NOT remove more rib material than necessary or camshaft
position sensor may be damaged. Due to high magnetic field
and possible electrical damage to camshaft position sensor,
DO NOT use electric grinder to remove rib material from
camshaft position sensor.
2) If no rib material exists, go to next step. If any rib
material exists, using razor knife, remove rib material from camshaft
end of camshaft position sensor until rib material is even with end of
camshaft position sensor.
CAUTION: DO NOT fabricate a paper spacer for camshaft end of camshaft
position sensor. Paper spacer from parts department is a
specified thickness for obtaining the correct camshaft
position sensor installation depth.
3) Ensure camshaft end of camshaft position sensor is clean.
Install NEW paper spacer from parts department on camshaft end of
camshaft position sensor. Use only specified paper spacer from parts
department for this camshaft position sensor application.
4) Apply light coat of engine oil on camshaft position sensor
"O" ring. Using a 1/2" wide metal ruler, measure distance from the
surface at camshaft position sensor mounting hole opening on timing
chain cover to the camshaft sprocket. See Fig. 15.
5) If distance is about 1.818" (46.18 mm), go to step 6). I\
f
distance is about 2.018" (51.26 mm), rotate engine by using crankshaft\
vibration damper retaining bolt until distance from the surface at
camshaft position sensor mounting hole opening on timing chain cover
to the camshaft sprocket is about 1.818" (46.18 mm). This will put the\
Page 960 of 1691
high machined area on camshaft sprocket toward the camshaft position
sensor. Go to next step.
CAUTION: Ensure proper measurement is obtained before installing
camshaft position sensor. DO NOT install camshaft position
sensor with low machined area on camshaft sprocket aligned
with camshaft position sensor mounting hole opening on timing
chain cover, or camshaft shaft position sensor will be
damaged when engine is started.
6) Using a slight rocking action, lightly push camshaft
position sensor into timing chain cover until paper spacer contacts
camshaft sprocket. DO NOT twist camshaft position sensor during
installation or "O" and paper spacer ring may be damaged. DO NOT
install camshaft position sensor retaining bolt at this time.
7) Using a scribe, place a scribe line on timing chain cover
at the end of slotted mounting hole on camshaft position sensor. See
Fig. 17 . This scribe line will be used as a reference when
reinstalling camshaft position sensor to obtain the correct camshaft
position sensor installation depth.
8) Remove camshaft position sensor from timing chain cover.
Remove paper spacer from camshaft end of camshaft position sensor.
Apply light coat of engine oil on camshaft position sensor "O" ring.
CAUTION: Camshaft position sensor must be positioned so end of slotted
mounting hole on camshaft position sensor aligns with scribe
line to provide proper camshaft position sensor installation
depth.
9) Using a slight rocking action, lightly push camshaft
position sensor into timing chain cover until end of slotted mounting
hole on camshaft position sensor aligns with scribe line on timing
chain cover. DO NOT twist camshaft position sensor during
installation, or "O" ring may be damaged.
10) Install and tighten camshaft position sensor retaining
bolt to specification. See TORQUE SPECIFICATIONS. Reinstall electrical
connector on camshaft position sensor.
Fig. 15: Locating Machined Areas On Camshaft Position Sensor &
Measuring Distance Between Camshaft Sprocket & Sensor Mounting Surface
(Ram Pickup 8.0L)
Courtesy of Chrysler Corp.
Page 970 of 1691
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
Page 971 of 1691
N - R EM OVE /IN STA LL/O VER HAU L
under FUEL SYSTEM. Disconnect negative battery cable. Ensure disconnect fitting and fuel lines are clean. Note location of releasetab and pull tab on disconnect fitting. See Fig. 24.
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. Removedisconnect fitting from fuel line. Inspect components for damage. Ifdisconnect fitting is damaged, entire assembly must be replaced, asonly pull tab may be replaced. 3) To install, ensure fuel line and disconnect fitting areclean. Lubricate fuel line and disconnect fitting with engine oil.Install disconnect fitting on fuel line until disconnect fittingbottoms on fuel line. 4) Install NEW pull tab until pull tab locks in disconnectfitting. DO NOT reuse old pull tab. Pull on fuel line and disconnectfitting to ensure components are properly locked together. Reconnectnegative battery cable. Start engine and check for leaks. Removal & Installation (Dual Tab)
1) Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM. Disconnect negative battery cable. Ensuredisconnect fitting and fuel lines are clean. Note location of tabs ondisconnect fitting. See Fig. 24.
2) Squeeze both tabs against disconnect fitting. Pulldisconnect fitting from fuel line. The plastic retainer will remain onthe fuel system component being serviced. The "O" rings and spacerwill remain in the disconnect fitting. 3) Inspect components for damage. If disconnect fitting isdamaged, entire assembly must be replaced. The only component that maybe replaced is the plastic retainer. If plastic retainer must beremoved from fuel system component, carefully release the plasticretainer from the fuel system component using 2 screwdrivers. Inspectplastic retainer for cracks or damage. Replace plastic retainer ifdefective. 4) To install, ensure fuel line and disconnect fitting areclean. 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 ensurecomponents are properly locked together. Reconnect negative batterycable. Start engine and check for leaks. Removal & Installation (Plastic Retainer Ring)
1) Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM. Disconnect negative battery cable. Ensuredisconnect fitting and fuel lines are clean. Note location of plasticretainer ring on disconnect fitting. See Fig. 24.
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. Withplastic retainer ring fully depressed, pull disconnect fitting fromfuel line. 3) Inspect components for damage. If disconnect fitting isdamaged, entire assembly must be replaced. 4) To install, ensure fuel line and disconnect fitting areclean. Lubricate fuel line and disconnect fitting with engine oil.Install disconnect fitting on fuel line until click sound is heard.
Page 972 of 1691
5) Pull on fuel line and disconnect fitting to ensure
components are properly locked together. Reconnect negative battery
cable. Start engine and check for leaks.
FUEL LINE AT FUEL RAIL
Removal & Installation (Dakota, Durango & Ram Pickup)
1) Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE
under FUEL SYSTEM. Disconnect negative battery cable.
2) Ensure area around fuel line fitting on fuel line and fuel
rail is clean. Using screwdriver, pry latch clip from fuel line
fitting and fuel rail while sliding latch clip toward fuel rail.
Perform STEP 1. See Fig. 25.
3) Insert Fuel Line Remover (Snap-On FIH-9055-1) into fuel
line fitting to release locking fingers inside fuel line fitting.
Perform STEP 2. See Fig. 25. Pull fuel line fitting with fuel line
from fuel rail.
4) Inspect fuel line fitting components for damage. If fuel
line fitting components are damaged, entire fuel line assembly must be
replaced.
5) To install, ensure fuel line fitting and fuel rail are
clean. Lubricate fuel line fitting and fuel rail with engine oil.
Install fuel line fitting on fuel rail until click sound is heard.
6) Install latch clip. Ensure latch clip snaps into position.
If latch clip will not fit properly, check for improper installation
of fuel line fitting on fuel rail. Pull on fuel line to ensure fuel
line fitting is properly locked on fuel rail. Reconnect negative
battery cable. Start engine and check for leaks.
Fig. 25: Disconnecting Fuel Line At Fuel Rail (Dakota, Durango &
Ram Pickup)
Courtesy of Chrysler Corp.
Removal & Installation (Ram Van & Ram Wagon)
Page 974 of 1691
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.
Page 977 of 1691
NOTE: Fuel level sensor may also be referred to as fuel gauge
sending unit.
Removal
1) Fuel level sensor is mounted on fuel pump module. See
Fig. 31 . Fuel pump module is located on top of fuel tank. See Figs. 27
-30.
2) Remove fuel pump module. See FUEL PUMP MODULE under FUEL
SYSTEM. Disconnect electrical connector for fuel pump and fuel level
sensor from electrical connector from bottom side of electrical
connector mounted on top of fuel pump module. See Fig. 31.
3) Remove locking collar from electrical connector for fuel
pump and fuel level sensor. Locking collar must be removed so wires
for fuel level sensor may be removed from the electrical connector for
fuel pump and fuel level sensor.
CAUTION: Note location of wires in electrical connector for fuel pump
and fuel level sensor for installation reference. Wires must
be installed in correct location.
4) Mark wire location in electrical connector for fuel pump
and fuel level sensor for installation reference. Remove wires for
fuel level sensor from electrical connector for fuel pump and fuel
level sensor.
5) Note location of notch and locking tab at end of fuel
level sensor. See Fig. 31. Carefully push locking tab away from notch
while sliding fuel level sensor down the channels, toward bottom of
fuel pump module. Note wire routing when removing fuel level sensor
from fuel pump module. Remove fuel level sensor.
Installation
1) Install fuel level sensor on channels of fuel pump module.
Ensure wires are properly routed. Slide fuel level sensor onto fuel
pump module until fuel level sensor snaps into place. Ensure locking
tab is fully seated.
2) Install wires for fuel level sensor in electrical
connector for fuel pump and fuel level sensor. Install locking collar.
Install electrical connector for fuel pump and fuel level sensor on
electrical connector on bottom side of electrical connector mounted on
top of fuel pump module. Reinstall fuel pump module. To complete
installation, reverse removal procedure.
Fig. 31: Locating Fuel Level Sensor, Fuel Pump & Fuel Pump Inlet
Strainer On Typical Fuel Pump Module
Courtesy of Chrysler Corp.
FUEL PRESSURE REGULATOR
Page 978 of 1691
Removal & Installation
Fuel pressure regulator is incorporated with the fuel filter.
For servicing for fuel filter/fuel pressure regulator, see FUEL
FILTER/FUEL PRESSURE REGULATOR.
FUEL PUMP
Removal & Installation
Fuel pump is incorporated into the fuel pump module. See FUEL
PUMP MODULE.
FUEL PUMP INLET STRAINER
Removal & Installation
1) Fuel pump inlet strainer is mounted on fuel pump module.
See Fig. 31 . Remove fuel pump module. See FUEL PUMP MODULE.
2) Spread locking tabs on bottom of fuel pump module and
remove fuel pump inlet strainer from fuel pump module. See Fig. 31.
Remove "O" ring from end of fuel pump module if "O" ring was not
removed with fuel pump inlet strainer.
3) To install, reverse removal procedure. Ensure "O" ring is
properly seated when installing fuel pump inlet strainer. Reinstall
fuel pump module using proper procedure.
FUEL PUMP MODULE
Removal (Dakota)
1) Fuel pump module is located on top of fuel tank. See
Fig. 27 . 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 arrow on fuel pump
module is at 7 o'clock position and aligns with reference mark on fuel
tank. See Fig. 33. Install and hand tighten fuel pump module lock nut.
3) Note location of fuel pressure regulator on fuel pump
module. See Fig. 27. 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.