DODGE RAM 1999 Service Repair Manual

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.

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)

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. Press sides of latch clip on fuel line fitting together
while rotating latch clip upward. See Fig. 26. Pull fuel line fitting
from fuel rail.
3) Inspect fuel line fitting for damage. If fuel line fitting
is damaged, entire fuel line assembly must be replaced.
4) 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.
5) Rotate latch clip downward so it snaps into position.
Ensure latch clip is fully snapped into position. If latch clip will
not snap into position, 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. 26: Disconnecting Fuel Line At Fuel Rail (Ram Van & Ram Wagon)
Courtesy of Chrysler Corp.
FUEL FILTER
Removal & Installation
Fuel filter is incorporated into the fuel pressure regulator.
A separate frame mounted fuel filter is not used. For servicing for
fuel filter/fuel pressure regulator, see FUEL FILTER/FUEL PRESSURE
REGULATOR.
FUEL FILTER/FUEL PRESSURE REGULATOR
Removal

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









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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









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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

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

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.

Fig. 32: Removing & Installing Typical Fuel Pump Module Lock Nut
(Dakota, Ram Pickup, Ram Van & Ram Wagon)
Courtesy of Chrysler Corp.
Fig. 33: Positioning Fuel Pump Module In Fuel Tank (Dakota)
Courtesy of Chrysler Corp.
Removal (Durango)
1) Fuel pump module is located on top of fuel tank. See

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)