1998 DODGE RAM 1500 Fuel pump replacement

FUEL FILTER / WATER
SEPARATOR
DESCRIPTION
The fuel filter/water separator assembly is located
on left side of engine above the starter motor. The
assembly also includes the fuel heater, Water-In-Fuel
(WIF) sensor, and fuel transfer pump.
OPERATION
The fuel filter/water separator protects the fuel
injection pump by removing water and contaminants
from the fuel. The construction of the filter/separator
allows fuel to pass through it, but helps prevent
moisture (water) from doing so. Moisture collects at
the bottom of the canister.
Refer to the maintenance schedules in the owners
manual for the recommended fuel filter replacement
intervals.
For draining of water from canister, refer to Fuel
Filter/Water Separator Removal/Installation section.
A Water-In-Fuel (WIF) sensor is attached to the
side of fuel filter housing. Refer to Water-In-Fuel
Sensor Description/Operation.
The fuel heater is installed into the top of the fil-
ter/separator housing. Refer to Fuel Heater Descrip-
tion/Operation.
REMOVAL
Refer to maintenance schedules in this manual, or
the owners manual for recommended fuel filter
replacement intervals.
Draining water from fuel filter/water separa-
tor housing:
The housing drain valve (Fig. 3) serves two pur-
poses. One is topartiallythe drain filter housing of
excess water. The other is tocompletelythe drain
housing for fuel filter, drain valve, heater element, ,
water-in-fuel sensor replacement or transfer pump
replacement.
The filter housing should be partially drained
whenever the water-in-fuel warning lamp remains
illuminated. (Note that lamp will be illuminated for
approximately two seconds when ignition key is ini-
tially placed in ON position for a bulb check).(1) A drain hose (Fig. 3) is located at the bottom of
drain valve. Place drain pan under drain hose.
(2)With engine not running,rotate drain valve
handle counter-clockwise (rearward) to OPEN
(DRAIN) position. Hold drain valve open until all
water and contaminants have been removed and
clean fuel exits.
(3) If drain valve, fuel heater element or Water-In-
Fuel (WIF) sensor is being replaced, drain housing
completely. Dispose of mixture in drain pan according
to applicable regulations.
(4) After draining operation, rotate valve handle
clockwise (forward) to the CLOSE position.
(5)Fuel Filter Replacement:The fuel filter is
located inside of the fuel filter housing.
(a) Clean all debris from around canister.
(b) Remove filter lid (Fig. 4) using a socket.
Attach socket to large hex on top of lid (Fig. 4).
Rotate counter-clockwise for removal. Remove
o-ring. Discard o-ring.
(c) Remove filter element by twisting element
sideways from filter lid.
(6)Water-In-Fuel (WIF) Sensor Replacement:
The WIF sensor is located on the side of the fuel fil-
ter housing (Fig. 3).
(a) Disconnect electrical connector at sensor.
(b) Clean area around sensor.
(c) Remove sensor by rotating counter-clockwise.
(d) Check condition of sensor o-ring. Replace if
damaged.
(7)Fuel Heater Element Replacement:The
heater element is located in the fuel filter housing
(Fig. 3).
(a) Remove fuel filter. See previous steps.
(b) Disconnect electrical connector.
(c) Remove two T-15 Torx head mounting screws
from fuel heater element.
(d) Remove fuel heater.
(8)Drain Valve Replacement:The drain valve
assembly is located on the side of the fuel filter hous-
ing (Fig. 3).
(a) Disconnect drain hose from the fuel drain
valve.
(b) Remove 4 drain valve mounting screws (T-15
Torx head).
(c) Remove drain valve from filter housing.
INSTALLATION
Refer to maintenance schedules for recommended
fuel filter replacement intervals.
(1) Thoroughly clean inside of filter housing, filter
cap and all related components.
(2)Fuel Filter:
(a)The engine has a self-priming low-pres-
sure fuel system. Refer to Standard Proce-
dures-Fuel System Priming.
ENGINE ROTATING (BARRING) TOOL - #7471B
(ALSO PART OF KIT #6860)
14 - 50 FUEL DELIVERY - DIESELDR
FUEL DELIVERY - DIESEL (Continued)

FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge sending unit (fuel level sensor) is
attached to the side of the fuel tank module. The
sending unit consists of a float, an arm, and a vari-
able resistor track (card).
OPERATION
The fuel tank module on diesel powered models
has 2 different circuits (wires). Two of these circuits
are used at the fuel gauge sending unit for fuel
gauge operation. The diesel engine does not have a
fuel tank module mounted electric fuel pump. The
electric fuel pump (fuel transfer pump) is mounted to
the engine.
For Fuel Gauge Operation:A constant input
voltage source of about 12 volts (battery voltage) is
supplied to the resistor track on the fuel gauge send-
ing unit. This is fed directly from the Engine Control
Module (ECM).NOTE: For diagnostic purposes,
this 12V power source can only be verified with
the circuit opened (fuel tank module electrical
connector unplugged). With the connectors
plugged, output voltages will vary from about .6
volts at FULL, to about 7.0 volts at EMPTY.The
resistor track is used to vary the voltage (resistance)
depending on fuel tank float level. As fuel level
increases, the float and arm move up, which
decreases voltage. As fuel level decreases, the float
and arm move down, which increases voltage. The
varied voltage signal is returned back to the ECM
through the sensor return circuit.
Both of the electrical circuits between the fuel
gauge sending unit and the ECM are hard-wired (not
multi-plexed). After the voltage signal is sent from
the resistor track, and back to the ECM, the ECM
will interpret the resistance (voltage) data and send
a message across the multi-plex bus circuits to the
instrument panel cluster. Here it is translated into
the appropriate fuel gauge level reading. Refer to
Instrument Panel for additional information.
REMOVAL
REMOVAL/INSTALLATION
For diesel removal and installation procedures,
refer to the gas section of Fuel System/Fuel Delivery.
See Fuel Level Sending Unit/Sensor Removal/Instal-
lation.
FUEL LINES
DESCRIPTION
Low-Pressure Lines Are:
²the fuel supply line from fuel tank to fuel trans-
fer (lift) pump.
²the fuel return line back to fuel tank.
²the fuel drain (manifold) line at rear of cylinder
head.
²the fuel supply line from fuel filter to fuel injec-
tion pump.
²the fuel injection pump return line.
High-Pressure Lines Are:
²the fuel line from fuel injection pump to fuel
rail.
²the 6 fuel lines from fuel rail up to injector con-
nector tubes
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 160,000 KPA (23,206
PSI). USE EXTREME CAUTION WHEN INSPECTING
FOR HIGH-PRESSURE FUEL LEAKS. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. HIGH FUEL INJECTION PRESSURE
CAN CAUSE PERSONAL INJURY IF CONTACT IS
MADE WITH THE SKIN.
OPERATION
High-Pressure Lines
CAUTION: The high-pressure fuel lines must be
held securely in place in their holders. The lines
cannot contact each other or other components. Do
not attempt to weld high-pressure fuel lines or to
repair lines that are damaged. If lines are ever
kinked or bent, they must be replaced. Use only the
recommended lines when replacement of high-pres-
sure fuel line is necessary.
High-pressure fuel lines deliver fuel (under pres-
sure) of up to approximately 160,000 kPa (23,206
PSI) from the injection pump to the fuel injectors.
The lines expand and contract from the high-pres-
sure fuel pulses generated during the injection pro-
cess. All high-pressure fuel lines are of the same
length and inside diameter. Correct high-pressure
fuel line usage and installation is critical to smooth
engine operation.
DRFUEL DELIVERY - DIESEL 14 - 57

WARNING: USE EXTREME CAUTION WHEN
INSPECTING FOR HIGH-PRESSURE FUEL LEAKS.
INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH
A SHEET OF CARDBOARD. HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
DIAGNOSIS AND TESTING - HIGH-PRESSURE
FUEL LINE LEAKS
High-pressure fuel line leaks can cause starting
problems and poor engine performance.
WARNING: DUE TO EXTREME FUEL PRESSURES
OF UP TO 160,000 kPa (23,206 PSI), USE EXTREME
CAUTION WHEN INSPECTING FOR HIGH-PRES-
SURE FUEL LEAKS. DO NOT GET YOUR HAND OR
A FINGER NEAR A SUSPECTED LEAK. INSPECT
FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET
OF CARDBOARD. HIGH FUEL INJECTION PRES-
SURE CAN CAUSE PERSONAL INJURY IF CON-
TACT IS MADE WITH THE SKIN.
Start the engine. Move the cardboard (Fig. 13) over
the suspected high-pressure fuel line leak, and check
for fuel spray onto the cardboard. If line is leaking,
retorque line. Replace damaged, restricted or leaking
high-pressure fuel lines with the correct replacement
line.
CAUTION: The high-pressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld high-pressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of high-pressure
fuel line is necessary.
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 from
both batteries. Cover and isolate ends of cables.(2) Thoroughly clean fuel lines at both ends.
(3) If removing fuel line at either #1 or #2 cylinder,
the intake manifold air heater elements must first be
removed from top of intake manifold. Refer to Intake
Air Heater Removal / Installation for procedures.
(4) If removing fuel line at #6 cylinder, a bracket
(Fig. 14) is located above fuel line connection at cyl-
inder head. Two bolts secure this bracket to rear of
cylinder head. The upper bolt hole is slotted. Loosen
(but do not remove) these 2 bracket bolts. Tilt
bracket down to gain access to #6 fuel line connec-
tion.
(5) Remove engine lift bracket (if necessary).
(6) Remove necessary insulated fuel line support
clamps (Fig. 15) and bracket bolts at intake manifold.
DO NOT remove insulators from fuel lines.
(7) Place shop towels around fuel lines at fuel rail
and injectors. If possible, do not allow fuel to drip
down side of engine.
CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE LINES ATTACHED TO A SEPA-
RATE FITTING (Fig. 16) , USE A BACK-UP WRENCH
ON FITTING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.
(8) Carefully remove each fuel line from engine.
Note position of each while removing.Do not bend
lines while removing.
Fig. 13 TYPICAL TEST FOR LEAKS USING
CARDBOARD
1 - HIGH-PRESSURE LINE
2 - CARDBOARD
3 - TYPICAL HIGH-PRESSURE FITTING
14 - 58 FUEL DELIVERY - DIESELDR
FUEL LINES (Continued)

IDENTIFICATION
Transmission identification numbers are stamped
on the left side of the case just above the oil pan gas-
ket surface (Fig. 2). Refer to this information when
ordering replacement parts.
GEAR RATIOS
The 48RE gear ratios are:
1st.................................2.45:1
2nd................................1.45:1
3rd................................1.00:1
4th.................................0.69:1
Rev.................................2.20:1
OPERATION
The application of each driving or holding compo-
nent is controlled by the valve body based upon the
manual lever position, throttle pressure, and gover-
nor pressure. The governor pressure is a variable
pressure input to the valve body and is one of the
signals that a shift is necessary. First through fourth
gear are obtained by selectively applying and releas-
ing the different clutches and bands. Engine power is
thereby routed to the various planetary gear assem-
blies which combine with the overrunning clutch
assemblies to generate the different gear ratios. The
torque converter clutch is hydraulically applied and
is released when fluid is vented from the hydraulic
circuit by the torque converter control (TCC) solenoid
on the valve body. The torque converter clutch is con-
trolled by the Powertrain Control Module (PCM). The
torque converter clutch engages in fourth gear, and
in third gear under various conditions, such as when
the O/D switch is OFF, when the vehicle is cruising
on a level surface after the vehicle has warmed up.
The torque converter clutch can also be engaged in
the MANUAL SECOND gear position if high trans-
mission temperatures are sensed by the PCM. The
torque converter clutch will disengage momentarily
when an increase in engine load is sensed by the
PCM, such as when the vehicle begins to go uphill or
the throttle pressure is increased. The torque con-
verter clutch feature increases fuel economy and
reduces the transmission fluid temperature.
Since the overdrive clutch is applied in fourth gear
only and the direct clutch is applied in all ranges
except fourth gear, the transmission operation for
park, neutral, and first through third gear will be
described first. Once these powerflows are described,
the third to fourth shift sequence will be described.
1 - TORQUE CONVERTER 10 - OVERDRIVE CLUTCH
2 - INPUT SHAFT 11 - DIRECT CLUTCH
3 - OIL PUMP 12 - PLANETARY GEAR
4 - FRONT BAND 13 - INTERMEDIATE SHAFT
5 - FRONT CLUTCH 14 - OVERDRIVE OVERRUNNING CLUTCH
6 - REAR CLUTCH 15 - DIRECT CLUTCH SPRING
7 - PLANETARIES 16 - OVERDRIVE PISTON RETAINER
8 - REAR BAND 17 - OIL PAN
9 - OVERRUNNING CLUTCH 18 - VALVE BODY
Fig. 2 Transmission Part Number And Serial
Number Location
1 - PART NUMBER
2 - BUILD DATE
3 - SERIAL NUMBER
21 - 134 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)

EVAPORATIVE EMISSIONS
TABLE OF CONTENTS
page page
EVAPORATIVE EMISSIONS
DESCRIPTION - EVAP SYSTEM............10
SPECIFICATIONS
TORQUE - EVAP SYSTEM...............11
CCV HOSE
DESCRIPTION - 8.0L V-10................12
OPERATION - 8.0L V-10..................12
EVAP/PURGE SOLENOID
DESCRIPTION.........................12
OPERATION...........................12
REMOVAL.............................12
INSTALLATION.........................12
FUEL FILLER CAP
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL
REMOVAL/INSTALLATION...............13
LEAK DETECTION PUMP
DESCRIPTION.........................13
OPERATION...........................14
REMOVAL.............................16
INSTALLATION.........................16ORVR
DESCRIPTION.........................17
OPERATION...........................17
P C V VA LV E
DESCRIPTION.........................17
OPERATION...........................19
DIAGNOSIS AND TESTING - PCV VALVE -
3.7L V-6/ 4.7L V-8......................20
REMOVAL.............................21
INSTALLATION.........................21
VACUUM LINES
DESCRIPTION.........................22
VAPOR CANISTER
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................22
INSTALLATION.........................22
NATURAL VAC LEAK DETECTION ASSY
DESCRIPTION.........................23
OPERATION...........................23
REMOVAL.............................24
INSTALLATION.........................25
EVAPORATIVE EMISSIONS
DESCRIPTION - EVAP SYSTEM
The evaporation control system prevents the emis-
sion of fuel tank vapors into the atmosphere. When
fuel evaporates in the fuel tank, the vapors pass
through vent hoses or tubes into the two charcoal
filled evaporative canisters. The canisters tempo-
rarily hold the vapors. The Powertrain Control Mod-
ule (PCM) allows intake manifold vacuum to draw
vapors into the combustion chambers during certain
operating conditions.
All gasoline powered engines use a duty cycle
purge system. The PCM controls vapor flow by oper-
ating the duty cycle EVAP purge solenoid. Refer to
Duty Cycle EVAP Canister Purge Solenoid for addi-
tional information.When equipped with certain emissions packages, a
Leak Detection Pump (LDP) will be used as part of
the evaporative system. This pump is used as a part
of OBD II requirements. Refer to Leak Detection
Pump for additional information. Other emissions
packages will use a Natural Vacuum Leak Detection
(NVLD) system in place of the LDP. Refer to NVLD
for additional information.
NOTE: The hoses used in this system are specially
manufactured. If replacement becomes necessary, it
is important to use only fuel resistant hose.
Certain EVAP system components can be found in
(Fig. 1).
25 - 10 EVAPORATIVE EMISSIONSDR

FUEL FILLER CAP
DESCRIPTION
The plastic fuel tank filler tube cap is threaded
onto the end of the fuel fill tube. Certain models are
equipped with a 1/4 turn cap.
OPERATION
The loss of any fuel or vapor out of fuel filler tube
is prevented by the use of a pressure-vacuum fuel fill
cap. Relief valves inside the cap will release fuel tank
pressure at predetermined pressures. Fuel tank vac-
uum will also be released at predetermined values.
This cap must be replaced by a similar unit if
replacement is necessary. This is in order for the sys-
tem to remain effective.
CAUTION: Remove fill cap before servicing any fuel
system component to relieve tank pressure. If
equipped with a Leak Detection Pump (LDP), or
NVLD system, the cap must be tightened securely.
If cap is left loose, a Diagnostic Trouble Code (DTC)
may be set.
REMOVAL
REMOVAL/INSTALLATION
If replacement of the 1/4 turn fuel tank filler tube
cap is necessary, it must be replaced with an identi-
cal cap to be sure of correct system operation.
CAUTION: Remove the fuel tank filler tube cap to
relieve fuel tank pressure. The cap must be
removed prior to disconnecting any fuel system
component or before draining the fuel tank.
LEAK DETECTION PUMP
DESCRIPTION
Vehicles equipped with JTEC engine control mod-
ules use a leak detection pump. Vehicles equipped
with NGC engine control modules use an NVLD
pump. Refer to Natural Vacuum - Leak Detection
(NVLD) for additional information.
The evaporative emission system is designed to
prevent the escape of fuel vapors from the fuel sys-
tem (Fig. 4). Leaks in the system, even small ones,
can allow fuel vapors to escape into the atmosphere.
Government regulations require onboard testing to
make sure that the evaporative (EVAP) system is
functioning properly. The leak detection system tests
for EVAP system leaks and blockage. It also performs
self-diagnostics. During self-diagnostics, the Power-
train Control Module (PCM) first checks the Leak
Detection Pump (LDP) for electrical and mechanical
faults. If the first checks pass, the PCM then uses
the LDP to seal the vent valve and pump air into the
system to pressurize it. If a leak is present, the PCM
will continue pumping the LDP to replace the air
that leaks out. The PCM determines the size of the
leak based on how fast/long it must pump the LDP
as it tries to maintain pressure in the system.
EVAP LEAK DETECTION SYSTEM COMPONENTS
Service Port: Used with special tools like the Miller
Evaporative Emissions Leak Detector (EELD) to test
for leaks in the system.
EVAP Purge Solenoid: The PCM uses the EVAP
purge solenoid to control purging of excess fuel
vapors stored in the EVAP canister. It remains closed
during leak testing to prevent loss of pressure.
EVAP Canister: The EVAP canister stores fuel
vapors from the fuel tank for purging.
EVAP Purge Orifice: Limits purge volume.
EVAP System Air Filter: Provides air to the LDP
for pressurizing the system. It filters out dirt while
allowing a vent to atmosphere for the EVAP system.
Fig. 3 EVAP / DUTY CYCLE PURGE SOLENOID
1 - MOUNTING BRACKET
2 - VACUUM HARNESS
3 - DUTY CYCLE SOLENOID
4 - TEST PORT CAP AND TEST PORT
DREVAPORATIVE EMISSIONS 25 - 13
EVAP/PURGE SOLENOID (Continued)

DEPLOYMENT - STANDARD
PROCEDURE, SERVICE AFTER A
SUPPLEMENTAL RESTRAINT............8O-7
DETECTION ASSY - DESCRIPTION,
NATURAL VAC LEAK..................25-23
DETECTION ASSY - INSTALLATION,
NATURAL VAC LEAK..................25-25
DETECTION ASSY - OPERATION,
NATURAL VAC LEAK..................25-23
DETECTION ASSY - REMOVAL, NATURAL
VAC LEAK..........................25-24
DETECTION PUMP - DESCRIPTION, LEAK . 25-13
DETECTION PUMP - INSTALLATION,
LEAK..............................25-16
DETECTION PUMP - OPERATION, LEAK . . . 25-14
DETECTION PUMP - REMOVAL, LEAK....25-16
DEVICES - STANDARD PROCEDURE,
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE........................8W-01-8
DIAGNOSTIC TROUBLE CODES -
DESCRIPTION........................25-1
DIAGNOSTICS (OBD) - DIAGNOSIS AND
TESTING, ON-BOARD...................7-5
DIAGRAMS - DESCRIPTION, HOW TO
USE WIRING......................8W-01-1
DIAGRAMS - HYDRAULIC SCHEMATICS,
SCHEMATICS.................21-176,21-337
DIESEL - CLEANING, RADIATOR - 5.9L....7-56
DIESEL - CLEANING, RADIATOR FAN -
5.9L................................7-35
DIESEL - CLEANING, WATER PUMP -
5.9L................................7-62
DIESEL - DESCRIPTION.................14-62
DIESEL - DESCRIPTION, 5.9L............11-3
DIESEL - DESCRIPTION, BELT
TENSIONER - 5.9L.....................7-23
DIESEL - DESCRIPTION, COOLING
SYSTEM FLOW - 5.9L...................7-3
DIESEL - DESCRIPTION, ENGINE 5.9L....9-232
DIESEL - DESCRIPTION, ENGINE BLOCK
HEATER - 5.9L........................7-37
DIESEL - DESCRIPTION, ENGINE
COOLANT THERMOSTAT - 5.9L...........7-46
DIESEL - DESCRIPTION, FAN DRIVE
VISCOUS CLUTCH - 5.9L...............7-52
DIESEL - DESCRIPTION, RADIATOR -
5.9L................................7-56
DIESEL - DESCRIPTION, TRANS COOLER
- 5.9L..............................7-68
DIESEL - DESCRIPTION, WATER PUMP -
5.9L................................7-62
DIESEL - FUEL INJECTOR FIRING ORDER . 14-48
DIESEL - INSPECTION, RADIATOR - 5.9L . . . 7-56
DIESEL - INSPECTION, RADIATOR FAN -
5.9L................................7-35
DIESEL - INSPECTION, TAILPIPE - 5.9L . . . 11-10
DIESEL - INSPECTION, WATER PUMP -
5.9L................................7-62
DIESEL - INSTALLATION................11-8
DIESEL - INSTALLATION...............14-62
DIESEL - INSTALLATION.....19-26,19-31,19-42
DIESEL - INSTALLATION, BELT
TENSIONER - 5.9L.....................7-24
DIESEL - INSTALLATION, DRIVE BELT -
5.9L
................................7-29
DIESEL - INSTALLATION, ENGINE BLOCK
HEATER - 5.9L
........................7-38
DIESEL - INSTALLATION, ENGINE
COOLANT THERMOSTAT - 5.9L
...........7-47
DIESEL - INSTALLATION, EXCEPT
........14-19
DIESEL - INSTALLATION, MUFFLER -
5.9L
...............................11-10
DIESEL - INSTALLATION, RADIATOR -
5.9L
................................7-57
DIESEL - INSTALLATION, RADIATOR FAN
- 5.9L
..............................7-36
DIESEL - INSTALLATION, TAILPIPE - 5.9L
. 11-11
DIESEL - INSTALLATION, WATER PUMP -
5.9L
................................7-62
DIESEL - MAINTENANCE SCHEDULES,
24-VALVE CUMMINS TURBO
.............0-12
DIESEL - OPERATION, BELT TENSIONER
- 5.9L
..............................7-23
DIESEL - OPERATION, ENGINE BLOCK
HEATER - 5.9L
........................7-38
DIESEL - OPERATION, ENGINE COOLANT
THERMOSTAT - 5.9L
...................7-46DIESEL - OPERATION, FAN DRIVE
VISCOUS CLUTCH - 5.9L...............7-52
DIESEL - OPERATION, RADIATOR - 5.9L . . . 7-56
DIESEL - OPERATION, TRANS COOLER -
5.9L................................7-69
DIESEL - OPERATION, WATER PUMP -
5.9L................................7-62
DIESEL - REMOVAL....................11-7
DIESEL - REMOVAL...................14-62
DIESEL - REMOVAL.........19-25,19-30,19-41
DIESEL - REMOVAL, BELT TENSIONER -
5.9L................................7-23
DIESEL - REMOVAL, DRIVE BELT - 5.9L....7-29
DIESEL - REMOVAL, ENGINE BLOCK
HEATER - 5.9L........................7-38
DIESEL - REMOVAL, ENGINE COOLANT
THERMOSTAT - 5.9L...................7-47
DIESEL - REMOVAL, EXCEPT...........14-17
DIESEL - REMOVAL, MUFFLER - 5.9L.....11-10
DIESEL - REMOVAL, RADIATOR - 5.9L.....7-56
DIESEL - REMOVAL, RADIATOR FAN -
5.9L................................7-35
DIESEL - REMOVAL, TAILPIPE - 5.9L.....11-10
DIESEL - REMOVAL, WATER PUMP -
5.9L................................7-62
DIESEL - SPECIFICATIONS, 5.9L.........9-244
DIESEL - TORQUE, FUEL SYSTEM -
EXCEPT.............................14-3
DIESEL ENGINE - DESCRIPTION, FUEL
REQUIREMENTS.......................0-1
DIESEL ENGINE - DIAGNOSIS AND
TESTING............................11-5
DIESEL ENGINE - DIAGNOSIS AND
TESTING, COOLING SYSTEM.............7-7
DIESEL ENGINE - INSTALLATION........8R-17
DIESEL ENGINE - INSTALLATION, 5.9L . . . 24-54,
24-58,24-72
DIESEL ENGINE - INSTALLATION,
EXCEPT............................8R-17
DIESEL ENGINE - REMOVAL............8R-16
DIESEL ENGINE - REMOVAL, 5.9L . . 24-53,24-56,
24-70
DIESEL ENGINE - REMOVAL, EXCEPT....8R-15
DIESEL ENGINE - STANDARD
PROCEDURE, DRAINING COOLING
SYSTEM 5.9L........................7-18
DIESEL ENGINE - STANDARD
PROCEDURE, REFILLING COOLING
SYSTEM 5.9L........................7-19
DIESEL ENGINE - TORQUE, FUEL
SYSTEM............................14-48
DIESEL ENGINE, SPECIAL TOOLS - 5.9L . . 9-246
DIESEL ENGINES - DESCRIPTION,
ENGINE OIL...........................0-2
DIESEL FUEL SYSTEM - DESCRIPTION . . . 14-45
DIESEL FUEL SYSTEM, SPECIAL TOOLS . . 14-49
DIESEL ONLY - ASSEMBLY, 5.9L..........7-70
DIESEL ONLY - DISASSEMBLY, 5.9L.......7-70
DIFFERENTIAL - ASSEMBLY . . . 3-129,3-156,3-47,
3-73,3-99
DIFFERENTIAL - DISASSEMBLY....3-128,3-155,
3-47,3-72,3-98
DIFFERENTIAL - INSTALLATION....3-130,3-157,
3-48,3-74,3-99
DIFFERENTIAL - REMOVAL
. . . 3-127,3-155,3-46,
3-72,3-97
DIFFERENTIAL CASE BEARINGS -
INSTALLATION
....3-106,3-134,3-161,3-48,3-75
DIFFERENTIAL CASE BEARINGS -
REMOVAL
........3-105,3-134,3-161,3-48,3-75
DIFFERENTIAL COVER - INSTALLATION
....3-97
DIFFERENTIAL COVER - REMOVAL
........3-97
DIFFERENTIAL TRAC-RITE - ASSEMBLY
. . 3-133,
3-161
DIFFERENTIAL TRAC-RITE - CLEANING
. . . 3-132,
3-160
DIFFERENTIAL TRAC-RITE -
DESCRIPTION
..................3-131,3-158
DIFFERENTIAL TRAC-RITE -
DISASSEMBLY
..................3-131,3-158
DIFFERENTIAL TRAC-RITE - INSPECTION
. 3-132,
3-160
DIFFERENTIAL TRAC-RITE - OPERATION
. . 3-131,
3-158
DIFFERENTIAL-TRAC-LOK - ASSEMBLY
. . . 3-103
DIFFERENTIAL-TRAC-LOK -
DESCRIPTION
.......................3-100DIFFERENTIAL-TRAC-LOK - DIAGNOSIS
AND TESTING.......................3-100
DIFFERENTIAL-TRAC-LOK -
DISASSEMBLY.......................3-101
DIFFERENTIAL-TRAC-LOK - OPERATION . . . 3-100
DIMENSIONS - SPECIFICATIONS, BODY
OPENING...........................23-99
DIMENSIONS - SPECIFICATIONS, FRAME . . 13-16
DIODE - INSTALLATION............8W-01-14
DIODE - REMOVAL................8W-01-14
DIODE REPLACEMENT - STANDARD
PROCEDURE........................24-45
DISC - INSTALLATION, CLUTCH...........6-5
DISC - REMOVAL, CLUTCH...............6-5
DISC BRAKE CALIPER ADAPTER MOUNT
- INSTALLATION......................5-22
DISC BRAKE CALIPERS - DESCRIPTION....5-16
DISC BRAKE CALIPERS - OPERATION.....5-16
DISC BRAKE ROTOR, DIAGNOSIS AND
TESTING............................5-32
DISCHARGE (ESD) SENSITIVE DEVICES -
STANDARD PROCEDURE,
ELECTROSTATIC...................8W-01-8
DISCHARGE LINE - DESCRIPTION, A/C....24-56
DISPLAY TEST MODE - DESCRIPTION,
STATE ..............................25-1
DISTRIBUTION - DESCRIPTION, POWER . 8W-97-1
DISTRIBUTION - OPERATION, POWER . . 8W-97-1
DISTRIBUTION DUCT - INSTALLATION,
FLOOR.............................24-34
DISTRIBUTION DUCT - REMOVAL,
FLOOR.............................24-33
DISTRIBUTION SYSTEMS, SPECIAL
TOOLS - POWER...................8W-97-2
DOME LAMP - DESCRIPTION...........8L-26
DOME LAMP - INSTALLATION..........8L-26
DOME LAMP - OPERATION.............8L-26
DOME LAMP - REMOVAL..............8L-26
DOOR - INSTALLATION...........23-18,23-28
DOOR - INSTALLATION, BLEND.........24-27
DOOR - INSTALLATION, DEFROST.......24-31
DOOR - INSTALLATION, FUEL FILL.......23-39
DOOR - INSTALLATION, MODE..........24-38
DOOR - INSTALLATION, RECIRCULATION . . 24-40
DOOR - REMOVAL...............23-18,23-28
DOOR - REMOVAL, BLEND.............24-27
DOOR - REMOVAL, DEFROST...........24-31
DOOR - REMOVAL, FUEL FILL..........23-39
DOOR - REMOVAL, MODE..............24-38
DOOR - REMOVAL, RECIRCULATION.....24-39
DOOR ACTUATOR - DESCRIPTION,
BLEND.............................24-17
DOOR ACTUATOR - DESCRIPTION,
DEFROST...........................24-20
DOOR ACTUATOR - DESCRIPTION,
MODE.............................24-23
DOOR ACTUATOR - DESCRIPTION,
RECIRCULATION.....................24-24
DOOR ACTUATOR - INSTALLATION,
BLEND.............................24-18
DOOR ACTUATOR - INSTALLATION,
DEFROST...........................24-21
DOOR ACTUATOR - INSTALLATION,
MODE.............................24-23
DOOR ACTUATOR - INSTALLATION,
RECIRCULATION.....................24-25
DOOR ACTUATOR - OPERATION, BLEND . . 24-17
DOOR ACTUATOR - OPERATION,
DEFROST...........................24-21
DOOR ACTUATOR - OPERATION, MODE . . . 24-23
DOOR ACTUATOR - OPERATION,
RECIRCULATION
.....................24-24
DOOR ACTUATOR - REMOVAL, BLEND
....24-17
DOOR ACTUATOR - REMOVAL, DEFROST
. . 24-21
DOOR ACTUATOR - REMOVAL, MODE
....24-23
DOOR ACTUATOR - REMOVAL,
RECIRCULATION
.....................24-24
DOOR AJAR INDICATOR - DESCRIPTION
. . 8J-23
DOOR AJAR INDICATOR - OPERATION
....8J-23
DOOR AJAR SWITCH - DESCRIPTION
....8L-27
DOOR AJAR SWITCH - OPERATION
......8L-27
DOOR GLASS - INSTALLATION
.....23-20,23-30
DOOR GLASS - REMOVAL
........23-20,23-30
DOOR GLASS RUN WEATHERSTRIP -
INSTALLATION, FRONT
................23-92
DOOR GLASS RUN WEATHERSTRIP -
INSTALLATION, REAR
.................23-93
10 INDEXDR
Description Group-Page Description Group-Page Description Group-Page

FIRING ORDER / CABLE ROUTING, 5.7L
V-8 ENGINE..........................8I-4
FIRING ORDER, 3.7L V-6 - ENGINE........8I-4
FIRING ORDER, 4.7L V-8 - ENGINE........8I-4
FIRING ORDER, DIESEL - FUEL
INJECTOR..........................14-48
FITTING - DESCRIPTION, QUICK
CONNECT............................14-8
FITTING - STANDARD PROCEDURE,
CONNECTING ROD BEARING...........9-129
FITTING - STANDARD PROCEDURE,
CRANKSHAFT MAIN BEARING.....9-134,9-207
FITTING - STANDARD PROCEDURE,
PISTON...................9-139,9-211,9-51
FITTING - STANDARD PROCEDURE,
PISTON RING.........9-142,9-213,9-284,9-53
FITTING, STANDARD PROCEDURE -
CONNECTING ROD BEARING............9-49
FITTING, STANDARD PROCEDURE -
MAIN BEARING.......................9-44
FITTINGS - STANDARD PROCEDURE,
HANDLING TUBING...................24-45
FITTINGS - STANDARD PROCEDURE,
QUICK-CONNECT......................14-8
FLAG - INSTALLATION, SIDE VIEW
MIRROR...........................23-27
FLAG - REMOVAL, SIDE VIEW MIRROR . . . 23-27
FLARING - STANDARD PROCEDURE,
DOUBLE INVERTED....................5-10
FLARING - STANDARD PROCEDURE, ISO . . . 5-11
FLEX PLATE - INSTALLATION . . 9-138,9-210,9-48
FLEX PLATE - REMOVAL.......9-138,9-210,9-48
FLOOR - INSTALLATION, LOAD..........23-72
FLOOR - REMOVAL, LOAD.............23-71
FLOOR CONSOLE - INSTALLATION.......23-67
FLOOR CONSOLE - REMOVAL...........23-67
FLOOR DISTRIBUTION DUCT -
INSTALLATION.......................24-34
FLOOR DISTRIBUTION DUCT - REMOVAL . 24-33
FLOOR MATS - INSTALLATION, CARPETS . 23-65
FLOOR MATS - REMOVAL, CARPETS.....23-65
FLOOR SHIFT BOOT - INSTALLATION,
4WD ..............................23-62
FLOOR SHIFT BOOT - REMOVAL, 4WD....23-62
FLOOR SUPPORT CYLINDER -
INSTALLATION, LOAD.................23-72
FLOOR SUPPORT CYLINDER -
REMOVAL, LOAD.....................23-72
FLOW - 5.9L DIESEL - DESCRIPTION,
COOLING SYSTEM.....................7-3
FLOW - DIAGNOSIS AND TESTING,
RADIATOR COOLANT..............7-54,7-56
FLOW 3.7L/4.7L/5.7L ENGINE -
DESCRIPTION, COOLING SYSTEM.........7-1
FLOW AND PRESSURE - DIAGNOSIS
AND TESTING, POWER STEERING........19-4
FLUID - DESCRIPTION................19-43
FLUID - DESCRIPTION, AUTOMATIC
TRANSMISSION.......................0-4
FLUID - DESCRIPTION, POWER
STEERING............................0-3
FLUID - DIAGNOSIS AND TESTING,
CAUSES OF BURNT............21-201,21-366
FLUID - OPERATION, AUTOMATIC
TRANSMISSION.......................0-5
FLUID AND FILTER REPLACEMENT -
STANDARD PROCEDURE........21-203,21-367
FLUID CAPACITIES, SPECIFICATIONS.......0-5
FLUID CONTAMINATION - DIAGNOSIS
AND TESTING................21-202,21-366
FLUID CONTAMINATION - DIAGNOSIS
AND TESTING, BRAKE..................5-23
FLUID COOLER - INSTALLATION.........19-43
FLUID COOLER - REMOVAL............19-43
FLUID DRAIN AND REFILL - STANDARD
PROCEDURE.....21-441,21-476,21-507,21-537,
21-571
FLUID INDICATOR - DESCRIPTION,
WASHER
...........................8J-44
FLUID INDICATOR - OPERATION,
WASHER
...........................8J-44
FLUID LEAK - DIAGNOSIS AND TESTING,
CONVERTER HOUSING
.........21-144,21-318
FLUID LEVEL - DIAGNOSIS AND
TESTING, EFFECTS OF INCORRECT
.....21-201,
21-366
FLUID LEVEL - STANDARD PROCEDURE,
BRAKE
..............................5-23FLUID LEVEL CHECK - STANDARD
PROCEDURE.................21-202,21-366
FLUID LEVEL CHECKING - STANDARD
PROCEDURE, POWER STEERING........19-43
FLUID LEVEL SWITCH - DESCRIPTION,
WASHER............................8R-9
FLUID LEVEL SWITCH - INSTALLATION,
WASHER...........................8R-11
FLUID LEVEL SWITCH - OPERATION,
WASHER............................8R-9
FLUID LEVEL SWITCH - REMOVAL,
WASHER...........................8R-10
FLUID RESERVOIR - INSTALLATION.......5-24
FLUID RESERVOIR - REMOVAL..........5-23
FLUID, SPECIFICATIONS - BRAKE.........5-23
FLUSH - SPECIFICATIONS, GAP.........23-95
FLUSHING - STANDARD PROCEDURE,
COOLING SYSTEM CLEANING/
REVERSE............................7-17
FLUSHING POWER STEERING SYSTEM -
STANDARD PROCEDURE...............19-40
FLYWHEEL - ASSEMBLY................6-11
FLYWHEEL - DIAGNOSIS AND TESTING....6-10
FLYWHEEL - DISASSEMBLY.............6-11
FLYWHEEL - INSTALLATION.............6-11
FLYWHEEL - REMOVAL.................6-11
FOG LAMP - INSTALLATION............8L-12
FOG LAMP - REMOVAL................8L-12
FOG LAMP RELAY - DESCRIPTION.......8L-12
FOG LAMP RELAY - INSTALLATION........8L-13
FOG LAMP RELAY - OPERATION.........8L-13
FOG LAMP RELAY - REMOVAL..........8L-13
FOOTMANS LOOP BRACKETS -
INSTALLATION, SEAT BACK REAR.......23-85
FOOTMANS LOOP BRACKETS -
REMOVAL, SEAT BACK REAR...........23-85
FORM-IN-PLACE GASKETS AND
SEALERS - STANDARD PROCEDURE . . 9-239,9-9,
9-94
FRAME - INSTALLATION, GRILLE........23-40
FRAME - REAR - INSTALLATION, SEAT
CUSHION...........................23-85
FRAME - REAR - REMOVAL, SEAT
CUSHION...........................23-85
FRAME - REMOVAL, GRILLE............23-40
FRAME DIMENSIONS - SPECIFICATIONS . . 13-16
FRAME H-SECTION REPLACEMENT -
STANDARD PROCEDURE, REAR.........13-13
FRAME RAIL TIP REPLACEMENT -
STANDARD PROCEDURE, LIGHT DUTY
FRONT..............................13-4
FREE MODULE - INSTALLATION, HANDS . . . 8T-2
FREE MODULE - REMOVAL, HANDS.......8T-2
FRONT - INSTALLATION....5-16,5-21,5-22,5-34
FRONT - INSTALLATION...............22-14
FRONT - INSTALLATION, CRANKSHAFT
OIL SEAL.............9-136,9-208,9-275,9-46
FRONT - INSTALLATION, PROPELLER
SHAFT - HD...........................3-7
FRONT - INSTALLATION, PROPELLER
SHAFT- LD............................3-7
FRONT - INSTALLATION, SEAT..........23-81
FRONT - INSTALLATION, SEAT BACK
CUSHION / COVER...................23-82
FRONT - INSTALLATION, SEAT CUSHION
/ COVER............................23-83
FRONT - REMOVAL........5-13,5-17,5-21,5-33
FRONT - REMOVAL, CRANKSHAFT OIL
SEAL................9-135,9-208,9-275,9-46
FRONT - REMOVAL, PROPELLER SHAFT
- HD ................................3-7
FRONT - REMOVAL, PROPELLER SHAFT-
LD ..................................3-6
FRONT - REMOVAL, SEAT..............23-81
FRONT - REMOVAL, SEAT BACK
CUSHION / COVER...................23-82
FRONT - REMOVAL, SEAT CUSHION /
COVER.............................23-83
FRONT AIR DAM - INSTALLATION........13-2
FRONT AIR DAM - REMOVAL............13-2
FRONT AXLE - 9 1/4 AA -
ADJUSTMENTS
.......................3-59
FRONT AXLE - 9 1/4 AA - DIAGNOSIS
AND TESTING
........................3-54
FRONT AXLE - 9 1/4 AA - INSTALLATION
. . . 3-58
FRONT AXLE - 9 1/4 AA - REMOVAL
......3-57
FRONT AXLE - 9 1/4 AA - SPECIAL
TOOLS
..............................3-64FRONT AXLE - 9 1/4 AA -
SPECIFICATIONS......................3-63
FRONT AXLE - C205F - ADJUSTMENTS....3-32
FRONT AXLE - C205F - DIAGNOSIS AND
TESTING............................3-27
FRONT AXLE - C205F - INSTALLATION.....3-31
FRONT AXLE - C205F - REMOVAL........3-31
FRONT AXLE - C205F - SPECIAL TOOLS . . . 3-40
FRONT AXLE - C205F - SPECIFICATIONS . . . 3-39
FRONT BEARING - INSTALLATION,
OUTPUT SHAFT.....................21-216
FRONT BEARING - REMOVAL, OUTPUT
SHAFT............................21-216
FRONT BRAKE HOSE - INSTALLATION.....5-13
FRONT BUMPER - INSTALLATION.........13-2
FRONT BUMPER - REMOVAL............13-2
FRONT CENTER SEAT BELT -
INSTALLATION......................8O-31
FRONT CENTER SEAT BELT - REMOVAL . . 8O-30
FRONT CENTER SEAT BELT &
RETRACTOR - INSTALLATION...........8O-29
FRONT CENTER SEAT BELT &
RETRACTOR - REMOVAL..............8O-29
FRONT CLUTCH - ASSEMBLY..........21-207
FRONT CLUTCH - DESCRIPTION........21-205
FRONT CLUTCH - DISASSEMBLY.......21-205
FRONT CLUTCH - INSPECTION.........21-206
FRONT CLUTCH - OPERATION.........21-205
FRONT CONTROL MODULE -
DESCRIPTION.....................8W-97-5
FRONT CONTROL MODULE -
DESCRIPTION........................8E-5
FRONT CONTROL MODULE - DIAGNOSIS
AND TESTING.....................8W-97-5
FRONT CONTROL MODULE - DIAGNOSIS
AND TESTING........................8E-5
FRONT CONTROL MODULE -
INSTALLATION....................8W-97-6
FRONT CONTROL MODULE -
INSTALLATION........................8E-5
FRONT CONTROL MODULE - OPERATION . 8W-97-5
FRONT CONTROL MODULE - OPERATION . . 8E-5
FRONT CONTROL MODULE - REMOVAL . 8W-97-6
FRONT CONTROL MODULE - REMOVAL....8E-5
FRONT CROSSMEMBER - INSTALLATION . . 13-22
FRONT CROSSMEMBER - REMOVAL.....13-22
FRONT DOOR GLASS RUN
WEATHERSTRIP - INSTALLATION........23-92
FRONT DOOR GLASS RUN
WEATHERSTRIP - REMOVAL............23-92
FRONT DOOR INNER BELT MOLDING -
INSTALLATION.......................23-93
FRONT DOOR INNER BELT MOLDING -
REMOVAL..........................23-93
FRONT DOOR OUTER BELT MOLDING -
INSTALLATION.......................23-93
FRONT DOOR OUTER BELT MOLDING -
REMOVAL..........................23-92
FRONT FASCIA - INSTALLATION..........13-3
FRONT FASCIA - REMOVAL..............13-2
FRONT FENDER - INSTALLATION........23-39
FRONT FENDER - REMOVAL............23-39
FRONT FRAME RAIL TIP REPLACEMENT
- STANDARD PROCEDURE, LIGHT
DUTY...............................13-4
FRONT HOSE - REMOVAL...............5-12
FRONT MOUNT - INSTALLATION . . . 9-147,9-218,
9-287,9-59
FRONT MOUNT - REMOVAL . . 9-146,9-217,9-286,
9-58
FRONT OUTBOARD SEAT BELT BUCKLE -
INSTALLATION......................8O-38
FRONT OUTBOARD SEAT BELT BUCKLE -
REMOVAL..........................8O-37
FRONT OUTPUT SHAFT SEAL -
INSTALLATION . . . 21-442,21-477,21-508,21-538,
21-572
FRONT OUTPUT SHAFT SEAL -
REMOVAL . 21-441,21-477,21-507,21-537,21-572
FRONT PARKING BRAKE CABLE -
INSTALLATION........................5-38
FRONT PARKING BRAKE CABLE -
REMOVAL
...........................5-36
FRONT SEAL - INSTALLATION, OIL
PUMP
............................21-391
FRONT SEAL - REMOVAL, OIL PUMP
....21-391
FRONT SERVO - ASSEMBLY
...........21-209
FRONT SERVO - CLEANING
...........21-209
DRINDEX 13
Description Group-Page Description Group-Page Description Group-Page