1998 DODGE RAM 1500 light

(b) Install new o-ring to canister lid and lubri-
cate o-ring with clean engine oil.
(c) Position new element to canister lid. Place
this assembly into canister by rotating clockwise.
(d) Tighten cap to 34 N´m (25 ft. lbs.) torque. Do
not overtighten cap.
(3)Water-In-Fuel (WIF) Sensor:
(a) Install new o-ring seal to WIF sensor.
(b) Apply a light film of clean oil to o-ring seal.
(c) Install sensor into housing.
(d) Tighten sensor to 2.5 N´m (25 in. lbs.) torque.
(e) Connect electrical connector to WIF sensor.
(4)Fuel Heater Element:
(a) Install fuel heater into fuel filter housing.
(b) Install fuel heater thermostat into fuel filter
housing.
(c) Install fuel heater mounting screws and
tighten to 1-1.5 N´m (13 in. lbs.) torque.
(d) Connect electrical connector to fuel heater
thermostat.
(e) Install new filter cover O-ring onto fuel filter
housing cover and lubricate with clean engine oil.
(f) Tighten fuel filter housing cover (lid) to 34
N´m (25 ft. lbs.).
(5)Drain Valve:
(a) Install 2 new o-rings to valve and filter hous-
ing.
(b) Lubricate with silicon grease.
(c) Install fuel drain valve.
(d) Install 4 mounting screws and tighten to
1±1.5 N´m (8±13 in. lbs.) torque.
(e) Connect drain hose to drain valve.
(6) Start engine and check for leaks.
FUEL HEATER
DESCRIPTION
The fuel heater assembly is located on the side of
the fuel filter housing (Fig. 3).
The heater/element assembly is equipped with a
temperature sensor (thermostat) that senses fuel
temperature. This sensor is attached to the fuel heat-
er/element assembly.
OPERATION
The fuel heater is used to prevent diesel fuel from
waxing during cold weather operation.
When the temperature is below 45  8 degrees F,
the temperature sensor allows current to flow to the
heater element warming the fuel. When the temper-
ature is above 75  8 degrees F, the sensor stops cur-
rent flow to the heater element.
Battery voltage to operate the fuel heater element
is supplied from the ignition switch and through the
fuel heater relay. Also refer to Fuel Heater Relay.
Fig. 3 FILTER HOUSING
1 - FILTER HOUSING
2 - FUEL HEATER AND THERMOSTAT
3 - FUEL HEATER MOUNTING SCREWS
4 - FUEL HEATER ELEC. CONNECTOR
5 - WIF SENSOR
6 - WIF SENSOR ELEC. CONNECTOR
7 - DRAIN HOSE
8 - DRAIN VALVE MOUNTING SCREWS
9 - DRAIN VALVE
Fig. 4 FILTER COVER (LID)
1 - FILTER COVER
2 - ATTACH SOCKET HERE
DRFUEL DELIVERY - DIESEL 14 - 51
FUEL FILTER / WATER SEPARATOR (Continued)

This will ensure proper gear-to-shaft tighten-
ing.
(5) Clean pump gear and pump shaft at machined
tapers with an evaporative type cleaner such as
brake cleaner.
(6) Position injection pump to mounting flange on
gear housing while aligning injection pump shaft
through back of injection pump gear.
(7) After pump is positioned flat to mounting
flange, install 3 pump mounting nuts and tighten
finger tight only.Do not attempt a final tightening
at this time.Do not attempt to tighten (pull)
pump to gear housing using mounting nuts.
Damage to pump or gear cover may occur. The
pump must be positioned flat to its mounting
flange before attempting to tighten 3 mounting
nuts.
(8) To prevent damage or cracking of components,
install and tighten nuts in the following sequence:
(a) Install injection pump shaft washer and nut
to pump shaft. Tighten nutfinger tight only.
(b) Do preliminary (light) tightening of injection
pump shaft nut.
(c) Tighten 3 injection pump mounting nuts to
24 N´m (18 ft. lbs.).(d) Do a final tightening of pump shaft nut to
105 N´m (77 ft. lbs.).
(9) Install drive gear access cover (plate) using a
3/8º drive ratchet. Plate is threaded to timing gear
cover. Tighten to 8 N´m (71 in. lbs.) torque.
(10) Install fuel line (injection pump-to-pressure
limiting valve). Tighten bolts to 24 N´m (18 ft. lbs.)
torque.
(11) Install fuel line (injection pump-to-fuel rail).
(a) Tighten fitting at fuel pump to 37 N´m (27 ft.
lbs.) torque. Use a back-up wrench.
(b) Tighten fitting at fuel rail to 37 N´m (27 ft.
lbs.) torque.
(12) Install fuel line (injection pump-to-fuel filter
housing). Tighten to 24 N´m (18 ft. lbs.) torque.
(13) Connect Fuel Control Actuator (FCA) electri-
cal connector to rear of injection pump.
(14) Install intake manifold air intake tube (above
injection pump). Tighten clamps.
(15) Install accessory drive belt.
(16) Install cooling fan shroud.
(17) Install cooling fan assembly.
(18) Connect both negative battery cables to both
batteries.
(19) Check system for fuel or engine oil leaks.
Fig. 12 FUEL INJECTION PUMP REMOVAL/INSTALLATION
1 - PUMP DRIVE GEAR NUT
2 - WASHER
3 - PUMP DRIVE GEAR
4 - RUBBER O-RING
5 - FUEL INJECTION PUMP6 - PUMP MOUNTING NUTS (3)
7 - PUMP MOUNTING STUDS (3)
8 - O-RING MACHINED GROOVE
9 - FRONT TIMING GEAR HOUSING
14 - 56 FUEL DELIVERY - DIESELDR
FUEL INJECTION PUMP (Continued)

is the primary engine speed indicator for the engine
after the engine is running.
REMOVAL
The Camshaft Position Sensor (CMP) on the 5.9L
diesel engine is located below the fuel injection
pump. It is bolted to the back of the timing gear
housing (Fig. 9).
(1) Disconnect electrical connector at CMP sensor
(Fig. 9).
(2) Remove sensor mounting bolt.
(3) Carefully twist sensor from timing gear hous-
ing.
(4) Check condition of sensor o-ring.
INSTALLATION
(1) Clean out machined hole in back of timing gear
housing (cover).
(2) Apply a small amount of engine oil to sensor
o-ring.
(3) Install sensor into timing gear housing (cover)
with a slight rocking action. Do not twist sensor into
position as damage to o-ring may result.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to back of timingchain housing (cover). If sensor is not flush, dam-
age to sensor mounting tang may result.
(4) Install mounting bolt and tighten. Refer to
Torque Specifications.
(5) Connect electrical connector to sensor.
CRANKSHAFT POSITION
SENSOR
DESCRIPTION
The Crankshaft Position Sensor (CKP) on the die-
sel engine is attached at the front / left side of the
engine next to the engine harmonic balancer (crank-
shaft damper).
OPERATION
The Crankshaft Position Sensor (CKP) is the pri-
mary engine speed indicator for the engine after the
engine is running (Fig. 10). The CKP contains a hall
effect device. A rotating, notched target wheel (tone-
wheel) for the CKP is located on the engine harmonic
balancer (Fig. 11). This hall effect device detects
notches located on the tonewheel. As the tonewheel
rotates, the notches pass the tip of the CKP.
Fig. 8 5.9L DIESEL CMP
1 - CMP
2 - FUEL INJECTION PUMP (BOTTOM)
3 - ELECTRONIC CONTROL MODULE (ECM)
4 - ECM ELEC. CONNECTOR
5 - CMP ELEC. CONNECTOR
6 - CMP MOUNTING BOLT
7 - BACK OF TIMING GEAR HOUSING
Fig. 9 5.9L DIESEL CMP
1 - CMP
2 - FUEL INJECTION PUMP (BOTTOM)
3 - ELECTRONIC CONTROL MODULE (ECM)
4 - ECM ELEC. CONNECTOR
5 - CMP ELEC. CONNECTOR
6 - CMP MOUNTING BOLT
7 - BACK OF TIMING GEAR HOUSING
14 - 72 FUEL INJECTION - DIESELDR
CAMSHAFT POSITION SENSOR (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)

(8) Connect battery cables to both batteries.
(9) Start engine and check for leaks.
INLET AIR TEMPERATURE
SENSOR/PRESSURE SENSOR
DESCRIPTION
The combination, dual function Inlet Air Tempera-
ture/Pressure Sensor is located on the air cleaner (fil-
ter) cover.
OPERATION
The Inlet Air Temperature/Pressure Sensor is a
combination dual-function sensor. The sensor element
extends into the intake air stream at the top of the
air filter housing. Ambient air temperature as well as
barometric pressure is monitored by this sensor. The
Engine Control Module (ECM) monitors signals from
this sensor.
REMOVAL
The Inlet Air Temperature/Pressure Sensor is
located on the air cleaner cover (Fig. 23).
(1) Disconnect electrical connector at sensor (Fig.
24).
(2) Remove two Torx-type mounting screws.
(3) Remove sensor from air cleaner cover.
(4) Check condition of sensor o-ring (Fig. 25).
INSTALLATION
(1) Check condition of sensor o-ring.
(2) Position sensor into top of air cleaner cover
with a slight twisting action.
(3) Install 2 mounting screws.
(4) Install electrical connector.
Fig. 22 FUEL INJECTOR RAIL
1 - FUEL RAIL MOUNTING BOLTS (3)
2 - INSULATED CLAMPS
3 - FUEL INJECTOR RAIL
Fig. 23 IAT/PRESSURE SENSOR LOCATION - 5.9L
DIESEL
1 - CLIPS
2 - FILTER COVER
3 - FILTER MINDERŸ
4 - INLET AIR TEMPERATURE/ PRESSURE SENSOR
5 - FILTER HOUSING
DRFUEL INJECTION - DIESEL 14 - 79
FUEL INJECTOR RAIL (Continued)

(11) Remove the shift cable from the column shift
lever actuator (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - 32RH/GEAR SHIFT
CABLE - REMOVAL). (Fig. 3).
(12) Release the shift cable from the column
bracket and remove it from the bracket.
(13) Remove the SKIM module in order to discon-
nect the electrical connector.
(14) Remove the upper steering shaft coupler bolt
and slide the shaft down (Fig. 4) & (Fig. 5)(15) Remove the brake light switch and discard
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/BRAKE LAMP SWITCH - REMOVAL).
(16) Remove the four steering column mounting
nuts (Fig. 6).
Fig. 3 SHIFT CABLE CONNECTOR
1 - Shift lever
2 - Cable Connection
3 - Overdrive Electrical Wiring
4 - Mounting Screws
Fig. 4 COUPLER SHAFT
1 - MOUNTING HOLES
2 - COUPLER BOLT HOLE
Fig. 5 UPPER STEERING COUPLER
1 - STEERING COUPLER
2 - PINCH BOLT HOLE
Fig. 6 MOUNTING HOLES
1 - MOUNTING HOLES
19 - 8 COLUMNDR
COLUMN (Continued)

(17) Remove the steering column assembly from
the vehicle. (Fig. 7)
INSTALLATION
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 steering column on the dash panel
support and loosely install the mounting nuts.
(2) Firmly slide the steering column upward
against the studs in dash panel and hand tighten the
nuts.
(3) Install the steering shaft coupler on the steer-
ing shaft and loosely install anewbolt.
(4) Center steering column in dash opening and
tighten mounting nuts to 28 N´m (250 in. lbs.).
NOTE: Torque the upper left nut first then the lower
right nut. Then torque the lower left nut then the
upper right nut.
NOTE: A new bolt must be used for reinstallation.
(5) Tighten the coupler bolt to 57 N´m (42 ft. lbs.).(6) Install a new brake light switch (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL).
(7) Install the shifter cable. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 32RH/GEAR
SHIFT CABLE - INSTALLATION)
(8) Connect the wiring harness to the column.
(9) Install the SKIM module.
(10) Install the clockspring(Refer to 8 - ELECTRI-
CAL/RESTRAINTS/CLOCKSPRING - REMOVAL).
(11) Install the shrouds.
(12) Install the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - INSTALLA-
TION).
(13) Align the spline on the wheel hub to shaft.
(14) Then install the steering wheel and install a
newbolt. Tighten the bolt to 61 N´m (45 ft. lbs.).
(15) Install the airbag (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(16) Install the two steering wheel switches.
(17) Install the tilt lever handle.
(18) Install the negative battery terminal.
(19) Test the operation of the horn, Electronic
PRNDL Indicator, lights and any other functions that
are steering column operated.
IGNITION SWITCH
DESCRIPTION
The ignition switch is located on the steering col-
umn. It is used as the main on/off switching device
for most electrical components. The mechanical key
cylinder is used to engage/disengage the electrical
ignition switch.
OPERATION
Vehicles equipped with an automatic trans-
mission and a steering column mounted shifter:
an interlock device is located within the shift cable.
This interlock device is used to lock the transmission
shifter in the PARK position when the key cylinder is
in any position and the brake pedal is not depressed.
DIAGNOSIS AND TESTING - IGNITION SWITCH
TEST AND REPAIR
If the key removal effort is excessive on a vehicle
with a automatic transmission first adjust the shift
linkage, (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 46RE/GEAR SHIFT CABLE -
ADJUSTMENTS).
If the ignition switch effort is excessive remove the
ignition key cylinder from the steering column. (Refer
to 19 - STEERING/COLUMN/LOCK CYLINDER
Fig. 7 STEERING COLUMN
1 - Steering Wheel
2 - Key Cylinder
3 - Gear Shift Lever
4 - Steering Column
5 - Tilt Lever Cable
DRCOLUMN 19 - 9
COLUMN (Continued)

KEY CYLINDER
REMOVAL
The ignition key must be in the key cylinder for
cylinder removal.
(1) Disconnect negative cable from battery.
(2) Remove upper and lower covers (shrouds) from
steering column.
(3) Place shifter in PARK position.
(4) A retaining pin (Fig. 12) is located at side of
key cylinder assembly.
(a) Rotate key to RUN position.
(b) Press in on retaining pin while pulling key
cylinder from ignition switch (Fig. 13).
INSTALLATION
The ignition key must be in the key cylinder for
cylinder installation.
(1) Install the key cylinder into the housing using
care to align the end of the key cylinder with the
ignition switch.
(2) Push the key cylinder in until it clicks.
(3) Replace the upper and lower shrouds.
(4) Reconnect the battery.
GEAR SHIFT LEVER
REMOVAL
(1) Remove the kneeblocker. (Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER -
REMOVAL).
(2) Remove the upper and lower column shroud.
(3) Remove and discard the brake light switch.
(4) Loosen the column bolts and lower the column
enough to allow clearance for the gear shift lever
removal.
(5) Disconnect the overdrive switch harness (if
equipped).
(6) Disconnect the shift cable from the shift lever.
(7) Remove the SKIM.
(8) Remove the gear shift lever mounting screws
and remove the lever. (Fig. 14)
(9) Remove the blocker pin from the inhibit link
slot (Fig. 14).
INSTALLATION
(1) Install the lever assembly using care to install
the pin in the blocker to slider slot (Fig. 15) and
install the mounting screws and tighten to 12 N´m
(105 in. lbs.).
Fig. 12 KEY CYLINDER
1 - KEY
2 - KEY CYLINDER
3 - RETAINING PIN HOLE
Fig. 13 KEY CYLINDER
1 - KEY CYLINDER
2 - PUNCH
Fig. 14 GEAR SHIFT LEVER
1 - PARK INHIBIT BLOCKER SPRING
2 - GEAR SHIFT LEVER
19 - 12 COLUMNDR