1998 DODGE RAM 1500 vin

(3) Remove valve cover. Refer to Engines for proce-
dures.
(4) Remove necessary high pressure fuel line con-
necting necessary fuel injector rail to high pressure
connector. Refer to Fuel Line Removal for procedures.
(5) A connector retainer (nut) (Fig. 15) is used on
each connector tube. Remove this nut(s) by unthread-
ing from cylinder head.
(6) Using special high-pressure connector removal
tool #9015 (Fig. 16), or (Fig. 17) remove necessary
high-pressure connector(s) from cylinder head. Tool
#9015 threads onto connector tube. Use tool to pry
connector tube(s) from cylinder head.
(7) Remove necessary exhaust rocker arm assem-
bly(s).
(8) Disconnect injector solenoid wire nuts at top of
injectors (Fig. 18).
(9) Remove 2 fuel injector hold-down clamp bolts
at each injector being removed.
(10)USING TOOL #9010:
(a) Special Tool #9010 (Fig. 19) is equipped with
2 clamshell clamps, a sliding retainer sleeve to
retain the clamshell clamps, a 2±piece mounting
stud, and a pivoting handle.Do not attempt to
remove the fuel injector with any other
device. Damage to injector will occur.
(b) The rocker housing (Fig. 18) is bolted to the
top of cylinder head. The mounting stud from tool
#9010 was meant to temporarily replace a rocker
housing mounting bolt. Remove the necessary
rocker housing mounting bolt. These mounting
bolts are located at the center of each of the 3
rocker housing support bridges.
(c) Install and tighten 2±piece mounting stud to
rocker housing. If removing the #6 fuel injector,
separate the 2±piece mounting stud. Install lower
half of mounting stud to center of rocker housing
bridge. Install upper half of mounting stud to lower
half.
(d) Position tool handle to mounting stud and
install handle nut. Leave handle nut loose to allow
a pivoting action.
(e) Position lower part of clamshell halves to
sides of fuel injector (wider shoulder to bottom).
The upper part of clamshell halves should also be
positioned into machined shoulder on the handles
pivoting head.
(f) Slide the retainer sleeve over pivoting handle
head to lock clamshell halves together.
(g) Be sure handle pivot nut is loose.
(h) Depress handle downward to remove fuel
injector straight up from cylinder head bore.
(11) Remove and discard injector sealing washer.
This should be located on tip of injector (Fig. 20) or
(Fig. 21).
Fig. 16 CONNECTOR TUBE REMOVAL
1 - CONNECTOR TUBE
2 - TOOL #9015
3 - CYLINDER HEAD (LEFT SIDE)
Fig. 17 TOOL #9015 AND CONNECTOR TUBE
1 - CONNECTOR TUBE
2 - LOCATING PINS
3 - RUBBER O-RING
4 - TOOL #9015
14 - 76 FUEL INJECTION - DIESELDR
FUEL INJECTOR (Continued)

INSTALLATION
(1)Inspect fuel injector:
(a) Look for burrs on injector inlet.
(b) Check nozzle holes for hole erosion or plug-
ging.
(c) Inspect end of nozzle for burrs or rough
machine marks.
(d) Look for cracks at nozzle end.
(e) If any of these conditions occur, replace injec-
tor.
(2) Thoroughly clean fuel injector cylinder head
bore. Blow out bore hole with compressed air.
(3) The bottom of fuel injector is sealed to cylinder
head bore with a copper sealing washer (shim) of acertain thickness (Fig. 20). A new shim with correct
thickness must always be re-installed after removing
injector. Measure thickness of injector shim (Fig. 21).
Shim Thickness: 1.5 mm (.060º)
(4) Install new shim (washer) to bottom of injector.
Apply light coating of clean engine oil to washer. This
will keep washer in place during installation.
(5) Install new o-ring to fuel injector. Apply small
amount of clean engine oil to o-ring.
Fig. 18 FUEL INJECTORS
1 - SOLENOID CONNECTIONS
2 - ROCKER HOUSING
3 - FUEL INJECTOR
4 - PASSTHROUGH CONNECTOR
Fig. 19 FUEL INJECTOR REMOVER - #9010
Fig. 20 FUEL INJECTOR SEALING WASHER (SHIM)
LOCATION
1 - FUEL INJECTOR
2 - COPPER SEALING WASHER (SHIM)
Fig. 21 MEASURING INJECTOR SEALING WASHER
(SHIM)
1 - SHIM
DRFUEL INJECTION - DIESEL 14 - 77
FUEL INJECTOR (Continued)

(6) Install injector into cylinder head with male
connector port facing the intake manifold. Push down
on fuel injector mounting flange to engage o-ring and
seat injector.
(7) Tightening Sequence:
(a) Install fuel injector holdown clamp (mount-
ing flange) bolts.Do a preliminary tightening
of these bolts to 5 N´m (44 in. lbs.) torque.
This preliminary tightening insures the fuel
injector is seated and centered.
(b) After tightening, relieve bolt torque, but
leave both bolts threaded in place.
(c) Install high-pressure connector and retaining
nut. Do a preliminary tightening to 15 N´m (11 ft.
lbs.) torque.
(d) Alternately tighten injector holdown bolts to
10 N´m (89 in. lbs.) torque.
(e) Do a final tightening of the high-pressure
connector and retaining nut. Tighten to 50 N´m (37
ft. lbs.) torque.
(8) Connect injector solenoid wires and nuts to top
of injectors (Fig. 18). Tighten connector nuts to 1.25
N´m (11 in. lbs.) torque.Be very careful not to
overtighten these nuts as damage to fuel injec-
tor will occur.
(9) Install exhaust rocker arm assembly. Refer to
Engine.
(10) Set exhaust valve lash. Refer to Engine.
(11) Install high pressure fuel line. Refer to Torque
Specifications.Be sure to use a secondary
back-up wrench on the connector nut (fitting)
while torquing fuel line fitting.Refer to Fuel Line
Installation for additional information.
(12) Install valve cover. Refer to Engine.
(13) Install breather assembly.
(14) Connect negative battery cables to both bat-
teries.
FUEL INJECTOR RAIL
DESCRIPTION
The fuel injector rail is bolted to the top of the
intake manifold.
OPERATION
The fuel rail is used as a distribution device to
supply high-pressure fuel to the high-pressure fuel
lines.
REMOVAL
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and pos-
sible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Disconnect both negative battery cables at both
batteries. Isolate ends of both cables.
(2) Disconnect electrical connector at fuel pressure
sensor.
(3) Remove banjo bolt at fuel limiting valve.
(4) Disconnect necessary wiring harness retention
clips from intake manifold.
(5) Lift 2 rubber covers to gain access to positive
(+), intake heater cable nuts. Remove 2 nuts and
remove 2 cables from studs.
(6) Carefully remove 4 high-pressure fuel lines
from top of injector rail engine. Note position of each
line while removing.Do not bend lines while
removing.
CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE LINES ATTACHED TO A SEPA-
RATE FITTING, USE A BACK-UP WRENCH ON FIT-
TING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.
(7) Carefully remove 2 high-pressure fuel lines at
each end of injector rail. Note position of each line
while removing.Do not bend lines while remov-
ing.
(8) Remove fuel line connecting injector pump to
fuel rail.
(9) Remove 3 injector rail mounting bolts (Fig. 22).
(10) Remove rail from top of intake manifold.
INSTALLATION
(1) Clean any dirt/debris from top of intake mani-
fold and bottom of fuel rail.
(2) Position fuel rail to top of manifold and install
3 mounting bolts. Refer to Torque Specifications.
(3) Install all high-pressure lines to rail. Refer to
Fuel Lines for procedures.
(4) Reposition wiring harness to intake manifold
and install new tie wraps.
(5) Install and tighten fuel limiting valve banjo
bolt. Refer to Torque Specifications.
(6) Connect electrical connector to fuel pressure
sensor.
(7) Position 2 positive (+) cables to intake heater
studs. Install 2 nuts.
14 - 78 FUEL INJECTION - DIESELDR
FUEL INJECTOR (Continued)

INTAKE AIR HEATER RELAY
DESCRIPTION
The 2 intake manifold air heater relays are located
in the engine compartment. They are attached to a
common bracket. This bracket is attached to the
right battery tray (Fig. 29).
OPERATION
The Engine Control Module (ECM) operates the 2
heating elements through the 2 intake manifold air
heater relays.
Refer to Powertrain Diagnostic Procedures for an
electrical operation and complete description of the
intake heaters, including pre-heat and post-heat
cycles.
REMOVAL
The 2 intake manifold air heater relays are located
in the engine compartment. They are attached to a
common bracket. This bracket is attached to the
right battery tray (Fig. 29).
The mounting bracket and both relays are replaced
as an assembly.
(1) Disconnect both negative battery cables at both
batteries.
(2) Disconnect four relay trigger wires at both
relays. Note position of wiring before removing.
(3) Lift four rubber shields from all 4 cables.(4) Remove four nuts at cable connectors. Note
position of wiring before removing.
(5) Remove relay mounting bracket bolts and
remove relay assembly.
INSTALLATION
(1) Install relay assembly to battery tray. Tighten
mounting bolts to 4.5 N´m (40 in. lbs.) torque.
(2) Connect eight electrical connectors to relays.
(3) Connect battery cables to both batteries.
INTAKE AIR TEMPERATURE
SENSOR/MAP SENSOR
DESCRIPTION
The combination, dual function Intake Manifold
Air Temperature Sensor/MAP Sensor is installed into
the top of the intake manifold.
OPERATION
The combination, dual function Intake Manifold
Air Temperature Sensor/MAP Sensor is installed into
the top of the intake manifold with the sensor ele-
ment extending into the air stream.
The IAT portion of the sensor provides an input
voltage to the Engine Control Module (ECM) indicat-
ing intake manifold air temperature. The MAP por-
tion of the sensor provides an input voltage to the
ECM indicating turbocharger boost pressure.
REMOVAL
The combination, dual function Intake Manifold
Air Temperature Sensor/MAP (IAT/MAP) sensor is
installed into the top of the intake manifold (Fig. 30).
(1) Clean area around sensor.
(2) Disconnect electrical connector from IAT/MAP
sensor.
(3) Remove two T-15 Torx headed screws.
(4) Remove sensor from intake manifold.
(5) Check condition of sensor o-ring (Fig. 31).
INSTALLATION
(1) Check condition of sensor o-ring.
(2) Lubricate sensor o-ring with clean engine oil.
(3) Clean sensor mounting area at intake mani-
fold.
(4) Position sensor into intake manifold.
(5) Install and tighten 2 sensor mounting screws
to 1 N´m (9 in. lbs.) torque.
(6) Connect electrical connector to sensor.
Fig. 29 INTAKE MANIFOLD AIR HEATER RELAYS
1 - BATTERY
2 - CABLES TO INTAKE HEATERS
3 - RELAY TRIGGER WIRES
4 - INTAKE AIR HEATER RELAYS (2)
14 - 82 FUEL INJECTION - DIESELDR

NOTE: When servicing the steering wheel after
removing the old bolt a new bolt must be used
when installing.
NOTE: When servicing the coupler a new bolt must
be used when installing.
DIAGNOSIS AND TESTING - STEERING
COLUMN
If the vehicle is involved in a front end collision/the
air bag has deployed the column must be inspected.
This inspection will determine if the Column has col-
lapsed. Inspect the column mounting capsules visu-
ally and manually push and pull them to check for
separation or fractures. If capsules are fractured or
have moved the column MUST be replaced.
REMOVAL
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. REFER TO ELECTRICAL RESTRAINT SYS-
TEM FOR SERVICE PROCEDURES. FAILURE TO DO
SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.CAUTION: All fasteners must be torqued to specifi-
cation to ensure proper operation of the steering
column.
(1) Position the front wheelsstraight ahead.
(2) Disconnect the negative (ground) cable from
the battery.
(3) Remove the two switches from the steering
wheel.
(4) Remove the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(5) Remove the steering wheel with special tool
CJ98±1 or an appropriate steering wheel puller.
CAUTION: Ensure the puller bolts are fully engaged
into the steering wheel and not into the clock-
spring, before attempting to remove the wheel. Fail-
ure to do so may damage the steering wheel/
clockspring.
(6) Remove the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - REMOVAL).
(7) Remove the tilt lever.
(8) Remove the column shrouds (Fig. 2).
(9) Remove the clock spring, (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/CLOCKSPRING -
REMOVAL).
(10) Disconnect the wiring harness to the column.
Fig. 1 STEERING COLUMN
1 - LOCK CYLINDER
2 - GEAR SHIFT LEVER
3 - MOUNTING HOLES
4 - STEERING COLUMN
5 - TILT LEVER
Fig. 2 UPPER & LOWER SHROUDS
1 - UPPER SHROUD
2 - LOWER SHROUD
DRCOLUMN 19 - 7
COLUMN (Continued)

HOUSING - REMOVAL). Check the turning effort of
the key cylinder. If the ignition key cylinder effort is
excessive replace the key cylinder.
REMOVAL
SERVICE PRECAUTIONS
NOTE: The steering column on vehicles equipped
with an automatic transmission is not equipped
with an internal locking shaft with the ignition cyl-
inder. Alternative methods of locking the steering
wheel for service will have to be used.
The tilt and standard column (Fig. 8) have been
designed to be serviced as an assembly; without wir-
ing, switches, shrouds, steering wheel, etc. Most
steering column components can be serviced without
removing the steering column from the vehicle.
Safety goggles should be worn at all times when
working on steering columns.
To service the steering wheel, switches or airbag,
Refer to Electrical Restraints and follow all WARN-
INGS and CAUTIONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG ANDPOSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Do not hammer on steering column
shaft. This may cause damage to the shaft or bear-
ing.
CAUTION: Do not attempt to remove the pivot bolts
to disassemble the tilting mechanism.
The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before removing ignition switch.
(1) Remove the negative (ground) cable from the
battery.
(2) Disable the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(3) Remove the lower and upper shrouds.
(4) Remove key cylinder. (Refer to 19 - STEER-
ING/COLUMN/LOCK CYLINDER HOUSING -
REMOVAL).
(5) Disconnect the lower clockspring connectors.
(6) Remove the wire retainer from the tilt lever
bracket.
(7) Remove the tilt lever mounting screws to gain
access to the ignition switch mounting screws. (Fig.
9)
Fig. 8 STEERING COLUMN
1 - KEY CYLINDER
2 - GEAR SHIFT LEVER
3 - MOUNTING HOLES
4 - STEERING COLUMN
5 - IGNITION SWITCH
Fig. 9 IGNITION SWITCH WITH TILT
1 - IGNITION SWITCH
2 - TILT LEVER MECHANISM
19 - 10 COLUMNDR
IGNITION SWITCH (Continued)

TILT LEVER KNOB RELEASE
REMOVAL
(1) Remove the tilt lever handle.
(2) Remove the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - REMOVAL).
(3) Remove the lower shroud.
NOTE: Use special care not to pry on the clock-
spring electrical connector when removing or
installing the mounting screw located next to the
clockspring.
(4) Remove the two mounting screws from the tilt
lever knob release bracket (Fig. 22).
(5) Disconnect the electrical harness plastic
mounting tab from the the bracket (Fig. 22).
(6) Unsnap the cable from the bracket (Fig. 23).
(7) Remove the end of the cable from the tilt lever
knob release bracket (Fig. 24).
INSTALLATION
(1) Route the cable into the tilt lever release knob
bracket (Fig. 24).
(2) Snap the cable end into the bracket (Fig. 23).
NOTE: Use special care not to pry on the clock-
spring electrical connector when removing or
installing the mounting screw located next to the
clockspring.
NOTE: New screws should be used when installing
the tilt lever release knob bracket to the column.(3) Install the tilt lever release knob bracket to the
column and install the two new mounting screws
(Fig. 22) Tighten the two new screws to 4.5 N´m (40
in. lbs.).
(4) Install the electrical harness plastic mounting
tab to the bracket (Fig. 22).
(5) Install the lower shroud.
(6) Install the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - INSTALLA-
TION).
(7) Install the tilt lever handle.
Fig. 22 TILT LEVER KNOB RELEASE BRACKET
1 - TILT LEVER RELEASE KNOB BRACKET
2 - ELECTRICAL HARNESS TAB
3 - MOUNTING SCREWS (2)
Fig. 23 CABLE UNSNAPPED
1 - TILT LEVER RLEASE KNOB BRACKET
2 - TILT LEVER CABLE REMOVAL/INSTALL
Fig. 24 END OF CABLE TO THE TILT LEVER
RELEASE KNOB
1 - TILT LEVER RELEASE KNOB BRACKET
2 - END OF CABLE REMOVAL/INSTALL
19 - 16 COLUMNDR

CAUTION: Use care not to score the housing bore
when removing seals.
(15) Remove the snap ring with snap ring pliers
(Fig. 16).
(16) Using special tool slide hammer C-3752 with
adapter 8990 remove the oil seal (Fig. 17).
INSTALLATION
(1) Inspect the piston teflon seals for damage.
Replace if needed.
NOTE: To replace the teflon seals, use a pick to
remove the teflon o-ring and the rubber o-ringunderneath. Install a new rubber o-ring in the piston
seal grove and a new teflon o-ring over the top of it.
(2) Install the valve into the valve housing.
(3) Thread the retainer ring into the valve housing
(Fig. 18). Tighten to 97 N´m (72 ft. lbs.)
NOTE: It is very important to make sure to compen-
sate for the added length of the torque wrench
when torquing to proper specifications.
(4) Install the retainer ring set screw. Tighten to
2.26 N´m (20 in. lbs.)
(5) Clean the steering gear housing.
CAUTION: Valve assembly must be centered to the
housing (Fig. 19).
(6) Install the valve assembly into the steering
gear (Fig. 19). Tighten the new bolts to 54 N´m (40 ft.
lbs.)
Fig. 16 SNAP RING REMOVAL
1 - SNAP RING PLIERS
2 - SNAP RING
3 - VALVE HOUSING
Fig. 17 OIL SEAL REMOVAL
1 - SPECIAL TOOL
8990
WITH SLIDE HAMMER C-3752
2 - VALVE HOUSING
Fig. 18 RETAINER RING INSTALLATION
1 - VALVE HOUSING
2 - SPECIAL TOOL
3 - TORQUE WRENCH
Fig. 19 CENTERED GEAR TEETH
1 - GEAR INSTALLED WITH THE CENTER TOOTH CENTERED IN
HOLE
2 - VALVE HOUSING
DRGEAR - LINK/COIL 19 - 29
STEERING GEAR INPUT SHAFT SEAL (Continued)