fuel cap release DODGE RAM 1999 Service Repair Manual

Minimum Compression Pressure
Dakota
2.5L ........................................................ (1)
3.9L, 5.2L & 5.9L ............................. 100 psi (690 kPa)\
Durango ........................................ 100 psi (690 kPa)\
Ram Pickup ..................................... 100 psi (690 kPa)\
Ram Van Ram Wagon .............................. 100 psi (690 kPa)\
Maximum Variation Between Cylinders ............................ ( 1)
( 1) - Information is not available from manufacturer.









\









\









\









\









\









\









\







FUEL SYSTEM
FUEL PRESSURE RELEASE
WARNING: Fuel system is under high pressure. ALWAYS release fuel
pressure before attempting to open system for testing or
component replacement. DO NOT allow fuel to flow onto engine
or electrical parts while testing fuel system components.
Vehicles With Fuel Rail Test Port
1) Loosen fuel tank filler cap. Ensure ignition is off.
Remove protective cap from fuel rail test port.
2) Place one end of Fuel Pressure Release Hose (C-4799-1)
into an approved fuel container. Attach remaining end of hose to fuel
rail test port. Use care, as fuel system may be under pressure. Fuel
pressure will be released from fuel system. Remove hose, reinstall
protective cap, and fuel tank filler cap.
3) Wait 5 seconds. Use care when disconnecting fuel lines, as
some fuel pressure may still exist in fuel lines.
NOTE: One or more DTCs may set when fuel pump relay is removed.
Clear DTCs from PCM after fuel pressure release procedure. To
clear DTCs from PCM, see CLEARING DTCS under SELF-DIAGNOSTIC
SYSTEM in SELF-DIAGNOSTICS - JEEP, TRUCKS & RWD VANS
article.
Vehicles Without Fuel Rail Test Port
1) Remove gas cap. Using a non-metallic tool, open flapper
valve in filler neck to relieve pressure. Remove fuel pump relay from
Power Distribution Center (PDC). Relays are identified on label under
PDC cover. Start and run engine until it stalls. Attempt to start
engine. Continue restarting engine until it will no longer run. Turn
ignition off.
CAUTION: DO NOT supply power to fuel injector for more than 4 seconds,
or fuel injector may be damaged.
2) Disconnect any fuel injector connector. Connect a jumper
wire between either fuel injector terminal and positive battery
terminal. Connect another jumper wire to other fuel injector terminal.
Momentarily touch other end of jumper wire to negative battery
terminal.
3) Place a shop towel under fuel line quick-connector at fuel
rail. Use care when disconnecting fuel lines, as some fuel pressure
may still exist in fuel lines. Disconnect fuel line quick-connector.
Reinstall fuel pump relay in PDC. Clear DTCs from PCM. To clear DTCs
from PCM, see CLEARING DTCS under SELF-DIAGNOSTIC SYSTEM in SELF-
DIAGNOSTICS - JEEP, TRUCKS & RWD VANS article.
FUEL PRESSURE TEST

NOTE: For additional information on fuel pressure and fuel pump
testing procedures, see appropriate NO TROUBLE CODE (NTC)
TEST and NO START (NS) TEST in SELF-DIAGNOSTICS - JEEP,
TRUCKS & RWD VANS article.
Vehicles With Fuel Rail Test Port
1) Disconnect negative battery cable. Release fuel pressure.
See FUEL PRESSURE RELEASE. Install fuel pressure gauge with hose on
fuel pressure test port.
2) Start engine and allow to idle. Fuel pressure should be
44-54 psi (3.1-3.8 kg/cm
). If no fuel pressure exists and engine will
not start, fuel pump relay and control circuit may be defective. See
FUEL PUMP RELAY.
3) If fuel pressure exceeds specification, fuel pump is okay,
but fuel pressure regulator is defective. Replace fuel pressure
regulator. Fuel pressure regulator is incorporated with the fuel
filter. Fuel filter/fuel pressure regulator is located on top of fuel
tank, in fuel pump module. See REMOVAL, OVERHAUL & INSTALLATION -
TRUCKS & RWD VANS - GASOLINE article.
Vehicles Without Fuel Rail Test Port
1) Disconnect negative battery cable. Release fuel pressure.
See FUEL PRESSURE RELEASE. Fuel pressure gauge is installed between
fuel supply line and fuel line fitting on fuel rail.
2) To disconnect fuel supply line from fuel rail, ensure area
around fuel supply line and fuel rail are clean. Note direction of
latch clip installation. Latch clip is located on top of fuel supply
line at fuel rail. See Fig. 1. Using 2 screwdrivers, pry latch clip
upward, and remove from fuel rail.
3) Pull fuel supply line from fuel rail. Install Adapter
(6923) into fuel rail. Ensure adapter is fully seated in fuel rail.
Install latch clip into fuel rail, with latch clip fingers pointing
downward. If latch clip will not fully seat so latch clip fingers
extend downward below fitting on fuel rail, adapter may not be fully
seated in fuel rail.
4) Connect fuel supply line to adapter. Ensure fuel supply
line fully seats in adapter. Remove protective cap from test port, and
install Fuel Pressure Gauge/Hose (5069) at test port.
5) Start engine and allow to idle. Fuel pressure should be
44-54 psi (3.1-3.8 kg/cm
). If no fuel pressure exists and engine will
not start, fuel pump relay and control circuit may be defective. See
FUEL PUMP RELAY.
6) If fuel pressure exceeds specification, fuel pump is okay,
but fuel pressure regulator is defective. Replace fuel pressure
regulator. Fuel pressure regulator is incorporated with the fuel
filter. Fuel filter/fuel pressure regulator is located on top of fuel
tank, in fuel pump module. See REMOVAL, OVERHAUL & INSTALLATION -
TRUCKS & RWD VANS - GASOLINE article.
7) On all models, release fuel pressure. See FUEL PRESSURE
RELEASE. Remove latch clip. Remove test equipment. Before reinstalling
fuel supply line, ensure fuel supply line fitting and fitting on fuel
rail are clean.
8) Lubricate fuel supply line fitting and fitting on fuel
rail with engine oil. Install fuel supply line on fuel rail.
9) Install latch clip into fuel rail, with latch clip fingers
pointing downward. Ensure latch clip is fully seated. Latch clip
fingers should extend downward below fitting on fuel rail when fully
seated.
10) Pull on fuel supply line to ensure fuel supply line is
fully locked on fuel rail. Reinstall negative battery cable. Start
engine and check for fuel leaks.

TROUBLE SHOOTING
NOTE: To trouble shoot mechanical engine components, see
appropriate table in TROUBLE SHOOTING article in GENERAL
INFORMATION.
REMOVAL & INSTALLATION
CAUTION: When battery is disconnected, vehicle computer and memory
systems may lose memory data. Driveability problems may exist
until computer systems have completed a relearn cycle. See
COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION
before disconnecting battery.
NOTE: For installation reference, label all electrical connectors,
vacuum hoses and fuel lines before removal. Also place mating
marks on engine hood and other major assemblies before
removal.
FUEL PRESSURE RELEASE
CAUTION: Fuel system is under pressure. Pressure must be released
before servicing fuel system components.
Gasoline
1) Disconnect negative battery cable. Loosen fuel tank cap to
release tank pressure. Press on filler tube flap to relieve any
additional tank pressure.
NOTE: Fuel filler tube has spring-loaded flap located below fuel
fill cap to serve as secondary seal if fuel fill cap is not
tightened. It is part of EVAP monitor system when vehicle is
equipped with leak detection pump (LDP). Vehicle may be
equipped with flap installed into fuel filler tube even if
vehicle is NOT equipped with LDP and EVAP monitor system.
2) Remove fuel pump relay from Power Distribution Center
(PDC). For location of relay, refer to label on underside of PDC
cover. Start and run engine until it stalls. Attempt restarting engine
until it will no longer run.
3) Unplug connector from an injector. Attach one end of a
jumper wire (18 gauge or smaller) with alligator clips to either
injector terminal. Connect other end of jumper wire to positive side
of battery. Connect one end of a second jumper wire to remaining
injector terminal.
WARNING: Powering an injector for more than a few seconds will
permanently damage injector.
4) Touch other end of second jumper wire to negative terminal
of battery for no more than a few seconds. Place a rag below fuel
line. Disconnect quick-connect fitting at fuel rail. See FUEL LINE
DISCONNECT FITTINGS. Return fuel pump relay to PDC.
Compressed Natural Gas Fuel Tube Purging (5.2L)
1) Close control valve (clockwise) on all fuel cylinders.
Open manual shutoff valve (open when handle is parallel to fuel
tubes).
2) Start and operate engine until it runs out of fuel.
Attempt 3 more engine starts. If check valve or fuel fill receptacle

Fig. 2: Identifying Retainer Type Fuel Line Disconnect Fittings
Courtesy of Chrysler Corp.
ENGINE
Removal (Ram Van/Wagon)
1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect negative battery cable. Drain cooling system and engine
oil. Remove and discard oil filter.
2) Remove engine cover, air cleaner and oil dipstick.
Discharge A/C system (if equipped) using approved refrigerant
recovery/recycling equipment. Disconnect A/C lines at condenser, and
plug openings. Remove A/C compressor. Disconnect fan shroud.
3) Remove front bumper, grille and support brace. Disconnect
coolant hoses. Remove radiator, condenser and support as an assembly.
4) Remove upper fan shroud. Remove power steering pump with
hoses attached, and set aside. Remove air pump, spark plug wires and
distributor cap. Disconnect necessary electrical wiring, coolant hoses
and vacuum hoses. Disconnect fuel lines. See FUEL LINE DISCONNECT

FITTINGS. Remove air cleaner, throttle body, drive belts, generator,
fan and fan pulley. Remove lower fan shroud.
CAUTION: When removing engine, DO NOT lift engine by intake manifold.
5) Remove intake manifold. See INTAKE MANIFOLD. Raise and
support vehicle. Remove starter. Remove exhaust pipe and heat shields.
Disconnect transmission shift linkage. Remove crank sensor.
6) On A/T models, remove transmission inspection cover. Mark
torque converter-to-flexplate position for installation reference.
Remove torque converter-to-flexplate bolts. On M/T models, disconnect
clutch release mechanism at clutch housing.
7) Attach engine hoist to cylinder heads (at intake manifold
flanges). On all models, support transmission using a floor jack.
Remove transmission or clutch housing-to-cylinder block bolts. Remove
engine mount bolts. Remove engine out front of vehicle.
Installation
To install, reverse removal procedure. Tighten bolts/nuts to
specification. See TORQUE SPECIFICATIONS table. On A/T models, ensure
reference marks on torque converter and flexplate are aligned.
Evacuate and charge A/C system.
Removal ( Dakota 2WD, Durango 2WD, Grand Cherokee & Ram
Pickup)
1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect and remove battery. On all except Pickup, scribe hood
hinges for installation reference and remove hood.
2) On all models, drain cooling system. Disconnect coolant
hoses. Remove radiator, fan and shroud. Discharge A/C system (if
equipped) using approved refrigerant recovery/recycling equipment.
Disconnect A/C lines, and plug openings. On Pickup, remove upper core
support, transmission cooler and A/C condenser. On all models, remove
belt, air cleaner, vacuum lines, distributor cap and wiring.
3) Disconnect necessary electrical wiring. Disconnect fuel
lines. See FUEL LINE DISCONNECT FITTINGS. Remove throttle body and
linkage. Remove intake manifold. Remove starter, generator, charcoal
canister and horns. Disconnect power steering hoses (if equipped).
Raise and support vehicle. Drain oil. Disconnect exhaust pipe at
exhaust manifold.
4) On A/T models, remove transmission housing inspection
plate. Mark torque converter-to-flexplate position for installation
reference. Remove torque converter-to-flexplate bolts. Remove bracket
for transmission cooler lines.
NOTE: It may be necessary to remove manual transmission if
transmission cannot be supported using floor jack.
5) On M/T models, disconnect clutch release mechanism at
clutch housing. On all models, support transmission using a floor
jack. Remove transmission or clutch housing-to-cylinder block bolts.
Install engine lifting fixture, and attach chain.
CAUTION: When removing engine, DO NOT lift engine by intake manifold.
6) On Ram Pickup and Grand Cherokee, remove front engine
mount bolts. Remove engine from vehicle. On Dakota 2WD and Durango 2WD
models, remove front engine mount through-bolts. See Fig. 3. Remove
engine from vehicle.
Installation
To install, reverse removal procedure. Tighten bolts/nuts to
specification. See TORQUE SPECIFICATIONS table. On A/T models, ensure

reference marks on torque converter and flexplate are aligned.
Evacuate and charge A/C system.
Removal (Durango 4WD & Dakota 4WD)
1) Release fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect and remove battery. Scribe hood hinges for installation
reference and remove hood.
2) Drain cooling system. Disconnect coolant hoses. Remove
radiator, fan and shroud. Discharge A/C system (if equipped) using
approved refrigerant recovery/recycling equipment. Disconnect A/C
lines, and plug openings. Remove air cleaner, vacuum lines,
distributor cap and wiring.
3) Disconnect necessary electrical wiring. Disconnect fuel
lines. See FUEL LINE DISCONNECT FITTINGS. Disconnect accelerator
linkage. Remove throttle body. Remove starter and generator.
Disconnect power steering hoses. Raise and support vehicle. Drain oil.
Disconnect exhaust pipe at exhaust manifold.
NOTE: Engine, transmission and front axle are connected and
supported with insulators and brackets. See Fig. 3.
4) On left side, remove 2 bolts attaching differential pinion
nose bracket-to-bellhousing bolts. Remove pinion nose bracket-to-
adapter bolts (located on top of differential, near pinion). Separate
engine from engine mount by removing engine mount through-bolt and nut
located on top of engine mount.
5) On right side, remove 2 axle-to-bracket bolts and bracket-
to-bellhousing bolt. Separate engine from engine mount by removing
engine mount through-bolt and nut located on top of engine mount.
Remove engine from vehicle.

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.

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.

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

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