1998 DODGE RAM 1500 fuel fill door release

OPERATION
Fuel is returned through the fuel pump module
and back into the fuel tank through the fuel filter/
fuel pressure regulator. A separate fuel return line
from the engine to the tank is not used.
The fuel tank assembly consists of: the fuel tank,
fuel pump module assembly, fuel pump module lock-
nut/gasket, and fuel tank check valve (refer to Fuel
Tank Check Valve for information).
A fuel filler/vent tube assembly using a pressure/
vacuum, 1/4 turn fuel filler cap is used. The fuel
filler tube contains a flap door located below the fuel
fill cap.
Also to be considered part of the fuel system is the
evaporation control system. This is designed to
reduce the emission of fuel vapors into the atmo-sphere. The description and function of the Evapora-
tive Control System is found in Emission Control
Systems.
Both fuel filters (at bottom of fuel pump module
and within fuel pressure regulator) are designed for
extended service. They do not require normal sched-
uled maintenance. Filters should only be replaced if
a diagnostic procedure indicates to do so.
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fill cap.
Fig. 1 FUEL DELIVERY COMPONENTS
1 - FUEL TANK 8 - LDP FRESH AIR FILTER
2 - CHECK VALVE 9 - LEAK DETECTION PUMP
3 - LIQUID EXPANSION CHAMBER 10 - EVAP CANISTERS (2)
4 - FUEL FILTER / FUEL PRESSURE REGULATOR 11 - FUEL TANK STRAPS (2)
5 - QUICK-CONNECT FITTING AND FUEL LINE (TO ENGINE) 12 - CHECK VALVE
6 - EVAP LINE CONNECTION 13 - FUEL PUMP MODULE LOCK RING
7 - LEAK DETECTION PUMP FRESH AIR LINE 14 - FUEL PUMP MODULE
14 - 2 FUEL DELIVERY - GASDR
FUEL DELIVERY - GAS (Continued)

(15) Install air duct to air box.
(16) Connect battery cable to battery.
(17) Start engine and check for leaks.
5.7L V-8
(1) If fuel injectors are to be installed, refer to Fuel
Injector Removal/Installation.
(2) Clean out fuel injector machined bores in
intake manifold.
(3) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(4) Position fuel rail/fuel injector assembly to
machined injector openings in intake manifold.
(5) Guide each injector into intake manifold. Be
careful not to tear injector o-rings.
(6) Pushrightside of fuel rail down until fuel
injectors have bottomed on shoulders. Pushleftfuel
rail down until injectors have bottomed on shoulders.
(7) Install 4 fuel rail holdown clamps and 4 mount-
ing bolts. Refer to Torque Specifications.
(8) Position spark plug cable tray and cable assem-
bly to intake manifold. Snap 4 cable tray retaining
clips into intake manifold.
(9) Install all cables to spark plugs and ignition
coils.
(10) Connect electrical connector to throttle body.
(11) Install electrical connectors to all 8 ignition
coils. Refer to Ignition Coil Removal/Installation.
(12) Connect electrical connector to throttle body.
(13) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 17). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector.
(14) Connect fuel line latch clip and fuel line to
fuel rail. Refer to Quick-Connect Fittings.
(15) Install air resonator to throttle body (2 bolts).
(16) Install flexible air duct to air box.
(17) Connect battery cable to battery.
(18) Start engine and check for leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module, and (if equipped) cer-
tain ORVR components.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.Two check (control) valves are mounted into the
top of the fuel tank. Refer to Fuel Tank Check Valve
for additional information.
An evaporation control system is connected to the
fuel tank to reduce emissions of fuel vapors into the
atmosphere. When fuel evaporates from the fuel
tank, vapors pass through vent hoses or tubes to a
charcoal canister where they are temporarily held.
When the engine is running, the vapors are drawn
into the intake manifold. Certain models are also
equipped with a self-diagnosing system using a Leak
Detection Pump (LDP) and/or an On-Board Refueling
Vapor Recovery (ORVR) system. Refer to Emission
Control System for additional information.
REMOVAL- EXCEPT DIESEL
Fuel Tank Draining
WARNING: THE FUEL SYSTEM MAY BE UNDER
CONSTANT FUEL PRESSURE EVEN WITH THE
ENGINE OFF. THIS PRESSURE MUST BE
RELEASED BEFORE SERVICING FUEL TANK.
Two different procedures may be used to drain fuel
tank: through the fuel fill fitting on tank, or using
the DRBtscan tool. Due to a one-way check valve
installed into the fuel fill opening fitting at the tank,
the tank cannot be drained conventionally at the fill
cap.
The quickest draining procedure involves removing
the rubber fuel fill hose.
As an alternative procedure, the electric fuel pump
may be activated allowing tank to be drained at fuel
rail connection. Refer to DRB scan tool for fuel pump
activation procedures. Before disconnecting fuel line
at fuel rail, release fuel pressure. Refer to the Fuel
System Pressure Release Procedure for procedures.
Attach end of special test hose tool number 6541,
6539, 6631 or 6923 at fuel rail disconnection (tool
number will depend on model and/or engine applica-
tion). Position opposite end of this hose tool to an
approved gasoline draining station. Activate fuel
pump and drain tank until empty.
If electric fuel pump is not operating, fuel must be
drained through fuel fill fitting at tank. Refer to fol-
lowing procedures.
(1) Release fuel system pressure.
(2) Raise vehicle.
(3) Thoroughly clean area around fuel fill fitting
and rubber fuel fill hose at tank.
(4) If vehicle is equipped with 4 doors and a 6 foot
(short) box, remove left-rear tire/wheel.
(5) Loosen clamp (Fig. 23) and disconnect rubber
fuel fill hose at tank fitting. Using an approved gas
holding tank, drain fuel tank through this fitting.
DRFUEL DELIVERY - GAS 14 - 17
FUEL RAIL (Continued)

FRONT SERVO - DESCRIPTION.........21-208
FRONT SERVO - DISASSEMBLY........21-209
FRONT SERVO - INSPECTION..........21-209
FRONT SERVO - OPERATION..........21-208
FRONT SKID PLATE - INSTALLATION.....13-23
FRONT SKID PLATE - REMOVAL.........13-23
FRONT SUSPENSION - DESCRIPTION,
GEAR - INDEPENDENT................19-17
FRONT SUSPENSION - INSTALLATION,
GEAR - INDEPENDENT................19-18
FRONT SUSPENSION - REMOVAL, GEAR
- INDEPENDENT.....................19-17
FRONT SUSPENSION, SPECIAL TOOLS....2-12
FRONT TOW HOOK ASSEMBLY -
INSTALLATION.......................13-23
FRONT TOW HOOK ASSEMBLY -
REMOVAL..........................13-23
FRONT WHEEL SPEED SENSOR -
DESCRIPTION........................5-47
FRONT WHEEL SPEED SENSOR -
INSTALLATION........................5-48
FRONT WHEEL SPEED SENSOR -
OPERATION..........................5-47
FRONT WHEEL SPEED SENSOR -
REMOVAL...........................5-48
FRONT WHEELHOUSE SPLASH SHIELD -
INSTALLATION.......................23-41
FRONT WHEELHOUSE SPLASH SHIELD -
REMOVAL..........................23-41
FUEL CONTROL ACTUATOR -
DESCRIPTION.......................14-74
FUEL CONTROL ACTUATOR -
OPERATION.........................14-74
FUEL CONTROL ACTUATOR - REMOVAL . . . 14-74
FUEL DELIVERY - GAS - DESCRIPTION....14-1
FUEL DELIVERY - GAS - OPERATION......14-2
FUEL DRAIN CIRCUIT - OPERATION......14-67
FUEL FILL DOOR - INSTALLATION.......23-39
FUEL FILL DOOR - REMOVAL...........23-39
FUEL FILLER CAP - DESCRIPTION.......25-13
FUEL FILLER CAP - OPERATION.........25-13
FUEL FILTER - STANDARD
PROCEDURES, WATER DRAINING AT.....14-47
FUEL FILTER / WATER SEPARATOR -
DESCRIPTION.......................14-50
FUEL FILTER / WATER SEPARATOR -
INSTALLATION.......................14-50
FUEL FILTER / WATER SEPARATOR -
OPERATION.........................14-50
FUEL FILTER / WATER SEPARATOR -
REMOVAL..........................14-50
FUEL FILTER/PRESSURE REGULATOR -
DESCRIPTION........................14-5
FUEL FILTER/PRESSURE REGULATOR -
OPERATION..........................14-6
FUEL GAUGE - DESCRIPTION...........8J-26
FUEL GAUGE - OPERATION.............8J-26
FUEL HEATER - DESCRIPTION..........14-51
FUEL HEATER - DIAGNOSIS AND
TESTING...........................14-52
FUEL HEATER - OPERATION............14-51
FUEL HEATER RELAY - DESCRIPTION....14-52
FUEL HEATER RELAY - INSTALLATION....14-53
FUEL HEATER RELAY - OPERATION......14-52
FUEL HEATER RELAY - REMOVAL........14-52
FUEL INDICATOR - DESCRIPTION, LOW . . . 8J-30
FUEL INDICATOR - OPERATION, LOW.....8J-30
FUEL INJECTION PUMP - DESCRIPTION . . 14-53
FUEL INJECTION PUMP - INSTALLATION . . 14-55
FUEL INJECTION PUMP - OPERATION....14-53
FUEL INJECTION PUMP - REMOVAL......14-54
FUEL INJECTION PUMP TIMING -
DIAGNOSIS AND TESTING.............14-53
FUEL INJECTOR - DESCRIPTION....14-26,14-74
FUEL INJECTOR - INSTALLATION........14-77
FUEL INJECTOR - OPERATION.....14-26,14-74
FUEL INJECTOR - REMOVAL............14-75
FUEL INJECTOR FIRING ORDER, DIESEL . . 14-48
FUEL INJECTOR RAIL - DESCRIPTION....14-78
FUEL INJECTOR RAIL - INSTALLATION....14-78
FUEL INJECTOR RAIL - OPERATION
......14-78
FUEL INJECTOR RAIL - REMOVAL
.......14-78
FUEL LEVEL SENDING UNIT / SENSOR -
DESCRIPTION
...................14-57,14-6
FUEL LEVEL SENDING UNIT / SENSOR -
INSTALLATION
........................14-7
FUEL LEVEL SENDING UNIT / SENSOR -
OPERATION
.....................14-57,14-6FUEL LEVEL SENDING UNIT / SENSOR -
REMOVAL...........................14-7
FUEL LINE LEAKS - DIAGNOSIS AND
TESTING, HIGH-PRESSURE.............14-58
FUEL LINES - DESCRIPTION........14-57,14-7
FUEL LINES - INSTALLATION...........14-60
FUEL LINES - OPERATION..............14-57
FUEL LINES - REMOVAL...............14-58
FUEL PRESSURE LIMITING VALVE -
DESCRIPTION.......................14-61
FUEL PRESSURE LIMITING VALVE -
INSTALLATION.......................14-61
FUEL PRESSURE LIMITING VALVE -
OPERATION.........................14-61
FUEL PRESSURE LIMITING VALVE -
REMOVAL..........................14-61
FUEL PRESSURE SENSOR -
DESCRIPTION.......................14-60
FUEL PRESSURE SENSOR -
INSTALLATION.......................14-61
FUEL PRESSURE SENSOR - OPERATION . . 14-60
FUEL PRESSURE SENSOR - REMOVAL....14-60
FUEL PUMP - DESCRIPTION............14-11
FUEL PUMP - OPERATION.............14-11
FUEL PUMP MODULE - DESCRIPTION....14-11
FUEL PUMP MODULE - INSTALLATION . . . 14-12
FUEL PUMP MODULE - OPERATION......14-11
FUEL PUMP MODULE - REMOVAL.......14-12
FUEL PUMP RELAY - DESCRIPTION......14-27
FUEL PUMP RELAY - INSTALLATION.....14-28
FUEL PUMP RELAY - OPERATION........14-27
FUEL PUMP RELAY - REMOVAL.........14-28
FUEL PUMP RELAYS - DIAGNOSIS AND
TESTING, ASD........................8I-5
FUEL RAIL - DESCRIPTION.............14-12
FUEL RAIL - INSTALLATION............14-15
FUEL RAIL - OPERATION...............14-12
FUEL RAIL - REMOVAL................14-13
FUEL REQUIREMENTS - DIESEL ENGINE
- DESCRIPTION........................0-1
FUEL SENSOR - DESCRIPTION, WATER
IN ................................14-66
FUEL SENSOR - OPERATION, WATER IN . . 14-66
FUEL SENSOR - REMOVAL, WATER IN....14-66
FUEL SYSTEM - DESCRIPTION, DIESEL . . . 14-45
FUEL SYSTEM - DIESEL ENGINE -
TORQUE............................14-48
FUEL SYSTEM - EXCEPT DIESEL -
TORQUE............................14-3
FUEL SYSTEM PARTS - STANDARD
PROCEDURES, CLEANING..............14-47
FUEL SYSTEM PRESSURE RELEASE -
STANDARD PROCEDURE................14-2
FUEL SYSTEM PRESSURE,
SPECIFICATIONS......................14-3
FUEL SYSTEM PRIMING - STANDARD
PROCEDURE........................14-47
FUEL SYSTEM, SPECIAL TOOLS..........14-5
FUEL SYSTEM, SPECIAL TOOLS -
DIESEL............................14-49
FUEL TANK - DESCRIPTION............14-17
FUEL TANK - OPERATION..............14-17
FUEL TANK MODULE - DESCRIPTION.....14-63
FUEL TANK MODULE - INSTALLATION....14-64
FUEL TANK MODULE - OPERATION......14-63
FUEL TANK MODULE - REMOVAL........14-63
FUEL TRANSFER PUMP - DESCRIPTION . . 14-64
FUEL TRANSFER PUMP - INSTALLATION . . 14-65
FUEL TRANSFER PUMP - OPERATION....14-64
FUEL TRANSFER PUMP - REMOVAL......14-64
FULL SIZE, SPARE WHEEL WITH
MATCHING TIRE - DESCRIPTION........22-15
FUNCTIONS - DESCRIPTION, CIRCUIT . . 8W-01-6
FUSE - DESCRIPTION, IOD...........8W-97-6
FUSE - INSTALLATION, IOD..........8W-97-7
FUSE - OPERATION, IOD.............8W-97-6
FUSE - REMOVAL, IOD..............8W-97-7
FUSES POWERING SEVERAL LOADS -
STANDARD PROCEDURE, TESTING
FOR A SHORT TO GROUND ON......8W-01-10
GAP AND FLUSH - SPECIFICATIONS......23-95
GAS ENGINE - DIAGNOSIS AND TESTING
. . 11-4
GAS ENGINE - INSTALLATION
...........19-26
GAS ENGINE - REMOVAL
..............19-25
GAS ENGINES - CLEANING, RADIATOR
FAN
................................7-34
GAS ENGINES - DESCRIPTION, COOLANT
RECOVERY CONTAINER
................7-33GAS ENGINES - INSPECTION, RADIATOR
FAN ................................7-34
GAS ENGINES - INSTALLATION,
COOLANT RECOVERY CONTAINER........7-33
GAS ENGINES - INSTALLATION,
RADIATOR FAN.......................7-34
GAS ENGINES - OPERATION, COOLANT
RECOVERY CONTAINER................7-33
GAS ENGINES - REMOVAL, COOLANT
RECOVERY CONTAINER................7-33
GAS ENGINES - REMOVAL, RADIATOR
FAN ................................7-33
GAS ENGINES - STANDARD
PROCEDURE, DRAINING COOLING
SYSTEM - ALL........................7-17
GAS ENGINES - STANDARD
PROCEDURE, REFILLING COOLING
SYSTEM - ALL........................7-18
GASKET - DIAGNOSIS AND TESTING,
CYLINDER HEAD......................9-21
GASKET FAILURE - DIAGNOSIS AND
TESTING, CYLINDER HEAD.............9-199
GASKET SELECTION - STANDARD
PROCEDURE, HEAD...................9-281
GASKET SURFACE PREPARATION -
STANDARD PROCEDURE, ENGINE........9-10
GASKETS AND SEALERS - STANDARD
PROCEDURE, FORM-IN-PLACE . . . 9-239,9-9,9-94
GAUGE - DESCRIPTION, ENGINE
TEMPERATURE......................8J-24
GAUGE - DESCRIPTION, FUEL...........8J-26
GAUGE - DESCRIPTION, OIL PRESSURE . . 8J-33
GAUGE - DESCRIPTION, VOLTAGE.......8J-42
GAUGE - OPERATION, ENGINE
TEMPERATURE......................8J-24
GAUGE - OPERATION, FUEL............8J-26
GAUGE - OPERATION, OIL PRESSURE....8J-33
GAUGE - OPERATION, VOLTAGE.........8J-43
GAUGES - DIAGNOSIS AND TESTING,
PRESSURE..........................22-7
GAUGES INDICATOR - DESCRIPTION,
CHECK.............................8J-21
GAUGES INDICATOR - OPERATION,
CHECK.............................8J-21
GEAR - DESCRIPTION, CRANKSHAFT.....9-273
GEAR - INDEPENDENT FRONT
SUSPENSION - DESCRIPTION...........19-17
GEAR - INDEPENDENT FRONT
SUSPENSION - INSTALLATION..........19-18
GEAR - INDEPENDENT FRONT
SUSPENSION - REMOVAL..............19-17
GEAR - INSTALLATION................9-273
GEAR - INSTALLATION, PINION
GEAR/RING......................3-51,3-77
GEAR - LINK/COIL - DESCRIPTION.......19-20
GEAR - LINK/COIL - INSTALLATION......19-21
GEAR - LINK/COIL - OPERATION........19-20
GEAR - LINK/COIL - REMOVAL..........19-20
GEAR - REMOVAL....................9-273
GEAR - REMOVAL, PINION GEAR/RING....3-49,
3-75
GEAR HOUSING - INSTALLATION........9-300
GEAR HOUSING - REMOVAL............9-299
GEAR HOUSING COVER - INSTALLATION . . 9-301
GEAR HOUSING COVER - REMOVAL
.....9-301
GEAR INPUT SHAFT SEAL -
INSTALLATION, STEERING
.............19-29
GEAR INPUT SHAFT SEAL - REMOVAL,
STEERING
..........................19-27
GEAR SELECTOR INDICATOR -
DESCRIPTION
.......................8J-27
GEAR SELECTOR INDICATOR -
OPERATION
.........................8J-27
GEAR SHIFT LEVER - INSTALLATION
.....19-12
GEAR SHIFT LEVER - REMOVAL
.........19-12
GEAR, SPECIAL TOOLS - POWER
STEERING
..........................19-23
GEAR, SPECIFICATIONS - POWER
STEERING
..........................19-22
GEAR TO COOLER - INSTALLATION,
RETURN HOSE
.................19-44,19-45
GEAR TO COOLER - REMOVAL, RETURN
HOSE
.........................19-44,19-45
GEAR/RING GEAR - INSTALLATION,
PINION
.........................3-51,3-77
GEAR/RING GEAR - REMOVAL, PINION
....3-49,
3-75
14 INDEXDR
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