1999 DODGE RAM torque

gear. When installing pump, ensure dowel on mounting flange must align
with hole in front of pump. Ensure fuel injection pump is flat against
gear housing. Install 4 fuel injection pump-to-gear housing nuts
finger tight. DO NOT tighten nuts at this time.
CAUTION: DO NOT tighten pump to gear cover using mounting nuts. Damage
to pump or gear cover may result. Pump must be positioned
flat to mounting flange before attempting to tighten mounting
nuts.
4) Install fuel injection pump shaft washer and nut to pump
shaft finger tight. Position lower pump bracket and install 3 bolts
finger tight. Tighten fuel injection pump drive gear nut to
preliminary torque of 22 ft. lbs. (30 N.m). Tighten 4 fuel injection
pump nuts and 3 lower pump bracket-to-pump bolts to specification.
Tighten 2 engine bracket-to-engine bolts to specification. See TORQUE
SPECIFICATIONS Final tighten injection pump shaft nut. Use barring
tool to prevent engine from rotating.
5) Install plastic access cap to front gear cover. Using new
gaskets, install fuel return line and overflow valve to side of
injection pump. Tighten overflow valve to specification. See TORQUE
SPECIFICATIONS Using new gaskets, install fuel supply line to side of
injection pump and top of fuel filter housing. Tighten banjo bolts to
specification. TORQUE SPECIFICATIONS.
6) To complete installation, reverse removal procedure. Bleed
air from fuel system. See FUEL LINE BLEEDING.
FUEL TANK ROLLOVER VALVE
Removal
1) Fuel tank rollover valve is pressed into rubber grommet on
top of fuel tank module. See Fig. 7. Manufacturer recommends removing
fuel tank for access to fuel tank rollover valve.
NOTE: It may be necessary to disconnect fuel lines and electrical
connector from fuel tank module so fuel tank may be lowered
for access to fuel tank rollover valve.
2) Raise and support vehicle. Disconnect negative battery
cables. Drain fuel tank. Remove fuel tank filler tube bolts from body.
Support fuel tank with transmission jack. Remove fuel tank straps and
heat shields (if equipped).
NOTE: Manufacturer recommends replacing rubber grommet on fuel tank
module when servicing fuel tank rollover valve.
3) Slightly lower fuel tank for access to fuel tank rollover
valve. Disconnect electrical connector and fuel lines from fuel tank
module if necessary to gain access to fuel tank rollover valve. Use
proper procedure when disconnecting fuel lines. See FUEL LINE
DISCONNECT FITTINGS under FUEL SYSTEM.
4) Disconnect hose from fuel tank rollover valve. Pry one
side of fuel tank rollover valve from rubber grommet. Remove fuel tank
rollover valve. Remove rubber grommet.
Installation
1) To install, reverse removal procedure using NEW rubber
grommet. If fuel lines were disconnected, install fuel lines on fuel
tank module using proper procedure. See FUEL LINE DISCONNECT FITTINGS
under FUEL SYSTEM.
2) Reinstall fuel tank. Tighten fuel tank strap nuts to
specification. See TORQUE SPECIFICATIONS. Reconnect negative battery
cables.

FUEL TRANSFER PUMP
Removal
1) Disconnect negative battery cables. Clean area around
transfer pump and fuel lines. Remove starter. Place a drain pan below
pump. Disconnect fuel line fitting at fuel supply line. Remove support
bracket bolt at top of pump. Remove banjo bolts at front and rear of
pump.
2) Disconnect pigtail harness electrical connector from main
engine wiring harness. Remove 3 pump bracket nuts. Remove fuel
transfer pump.
Installation
1) Install new gaskets to fuel supply line, support bracket,
and banjo bolt at rear of pump. Install banjo bolt finger tight.
Install new gaskets to fuel line and banjo bolt at front of pump.
Position 3 pump studs into pump mounting bracket and install 3 nuts
finger tight. Install support bracket bolt finger tight.
2) Tighten bolts and nuts evenly to specification. See TORQUE
SPECIFICATIONS. Reconnect electrical connectors. Tighten fuel lines to
specification. Install starter and negative battery cables. Bleed low-
pressure fuel lines. See FUEL LINE BLEEDING under FUEL SYSTEM.
HIGH-PRESSURE FUEL LINES
CAUTION: High-pressure fuel lines must be clamped securely and routed
so they do not contact each other or any other components. DO
NOT weld or substitute high-pressure fuel lines. High
-pressure lines are same length and proper high-pressure fuel
line must be installed in specified area for proper engine
operation.
Removal
1) Disconnect negative battery cables. Remove nameplate
located above rocker lever covers. Disconnect necessary clamps from
high-pressure fuel lines.
2) Ensure area around each high-pressure fuel line nut is
clean. Mark high-pressure fuel line location for installation
reference. Remove high-pressure fuel line from fuel injector.
3) Remove high-pressure fuel lines from fuel injection pump.
Remove high-pressure fuel lines from engine, using care not to bend
the fuel line.
Installation
To install, reverse removal procedure. Ensure all high-
pressure fuel line nuts are tightened to specification at fuel
injector and fuel injection pump before tightening clamp bolts to
specification. Bleed high-pressure fuel lines. See FUEL LINE BLEEDING
under FUEL SYSTEM.
OVERFLOW VALVE
Removal & Installation
1) Disconnect negative battery cables. Ensure area around
overflow valve is clean. Remove valve from pump and banjo fitting.
Discard gaskets.
2) To install, reverse removal procedure using NEW gaskets.
Tighten overflow valve to specification. See TORQUE SPECIFICATIONS.
EMISSION SYSTEMS & SUB-SYSTEMS

INTAKE MANIFOLD AIR HEATER
Removal & Installation
1) Disconnect negative battery cables. Disconnect clamp and
rubber hose at air intake housing. Remove engine oil dipstick tube
mounting bolt and position dipstick tube aside. Disconnect heater
electrical cables at cable mounting studs. Remove 4 air intake housing
bolts. Remove air intake housing from top of intake manifold air
heater elements. See Fig. 13.
2) Remove heater element assembly from intake manifold. Clean
old gasket from air intake housing, intake manifold, and both sides of
engine block. To install, reverse removal procedure using NEW gaskets.
Tighten all bolts to specification. See TORQUE SPECIFICATIONS.
Fig. 13: Removing Intake Manifold Air Heater
Courtesy of Chrysler Corp.
INTAKE MANIFOLD AIR HEATER RELAYS

Removal & Installation
See INTAKE MANIFOLD AIR HEATER RELAYS under RELAYS &
SOLENOIDS.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Access Plug ................................................ 11 (15)\
AFC Line-To-Fuel Injection Pump Fitting .................... 18 (24)\
Air Inlet Housing Bolt ..................................... 18 (24)\
Engine Bracket-To-Engine Bolts ............................. 18 (24)\
Engine Coolant Temperature Sensor .......................... 40 (54)\
Engine Speed Sensor Nut .................................... 18 (24)\
Fuel Injection Pump Drive Gear Nut ....................... 125 (170)\
Fuel Injection Pump Lower Bracket-To-Pump Bolts ............ 18 (24)\
Fuel Injection Pump Mount Nuts ............................. 32 (43)\
Fuel Injector Retaining Nut ................................ 44 (60)\
Fuel Line-To-Fuel Heater Fitting ........................... 18 (24)\
Fuel Line-To-Fuel Transfer Pump ............................ 18 (24)\
Fuel Supply Line Banjo Bolt ................................ 18 (24)\
Fuel Tank Strap Nut ........................................ 30 (41)\
Fuel Transfer Pump Bolt .................................... 18 (24)\
High-Pressure Fuel Line Clamp Bolt ......................... 18 (24)\
High-Pressure Fuel Line Nut (At Injector) .................. 28 (38\
)
High-Pressure Fuel Line Nut (At Pump) ...................... 18 (24\
)
Intake Manifold Air Heater Housing Bolt .................... 18 (24)\
Intake Manifold Air Temperature Sensor ..................... 20 (27)\
Intake Manifold Cover Bolt ( 1) ............................. 18 (24)
Oil Fill Plug .............................................. 21 (29)\
Overflow Valve-To-Fuel Injection Pump ...................... 24 (33)\
Park/Neutral Switch ........................................ 25 (34)\
Plastic Fuel Tank Module Lock Nut .......................... 32 (43)\
Starter Mounting Bolt ...................................... 32 (43)\
Turbocharger Oil Drain Line Bolt ........................... 18 (24)\
Turbocharger Oil Supply Line Nut ........................... 11 (15)\
Turbocharger Retaining Nut ................................. 24 (33)\
INCH Lbs. (N.m)
Air Inlet Tube-To-Turbocharger Clamp Nut .................. 72 (8.1)\
Canister Nut ............................................ 120 (13.6)\
Condenser-To-Intercooler Nut ............................. 95 (10.7)\
Condenser-To-Intercooler Screw ........................... 95 (10.7)\
Drain Valve-To-Canister Bolt .............................. 40 (4.5)\
Exhaust Pipe-To-Turbocharger Clamp Nut .................... 72 (8.1)\
Fuel Bleed Bolt ........................................... 72 (8.1)\
Fuel Injector Drain Line Assembly Retaining Clamp Bolt .. 120 (13.6)\
Fuel Injector Drain Line-To-Fuel Injector Banjo Bolt ...... 84 (9.5)\
Intake Manifold Air Heater Relay Assembly Retaining Bolt .. 40 (4.5)\
Intercooler Bolt .......................................... 17 (1.9)\
Intercooler Inlet & Outlet Duct Clamp ..................... 72 (8.1)\
PCM Mounting Bolt ......................................... 35 (4.0)\
Water-In-Fuel (WIF) Sensor ................................ 20 (2.3\
)
( 1) - Apply thread sealant to bolt threads.









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N - R EM OVE/IN STA LL/O VER HAU L - R W D - G ASO LIN E

1999 D odge P ic ku p R 1500
1999 ENGINE PERFORMANCE
CHRY - Removal, Overhaul & Installation - Gasoline
Dakota, Durango, Ram Pickup, Ram Van, Ram Wagon
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.
INTRODUCTION
Removal, overhaul and installation procedures are covered in
this article. If component removal and installation is basically an
unbolt and bolt-on procedure, only a torque specification may be
provided.
COMPUTERIZED ENGINE CONTROLS
POWERTRAIN CONTROL MODULE (PCM)
NOTE: If replacing Powertrain Control Module (PCM), the correct
vehicle mileage and Vehicle Identification Number (VIN) must
be programmed into the PCM to prevent Diagnostic Trouble
Codes (DTCs) from being set in the Anti-Lock Brake System
(ABS) module and Supplemental Restraint System (SRS) module\
.
To program PCM and clear DTCs from ABS and SRS modules, see
PCM PROGRAMMING. If replacing Powertrain Control Module (PCM)\
on models equipped with a Smart Key Immobilizer Module
(SKIM), the secret key data must also be updated to enable
engine starting. To update secret key data, see PCM
PROGRAMMING.
Removal & Installation
1) PCM is located in the engine compartment. See Figs. 1-3.
Disconnect negative battery cable. Remove cover for access to
electrical connectors at PCM. Disconnect electrical connectors from
PCM. Remove PCM retaining bolts and PCM.
2) To install, reverse removal procedure. Tighten PCM
retaining bolts to specification. See TORQUE SPECIFICATIONS.
Fig. 1: Locating PCM (Dakota & Durango)
Courtesy of Chrysler Corp.

Removal
Downstream oxygen sensor is mounted on exhaust pipe, behind
catalytic converter. Raise and support vehicle. Disconnect electrical
connector for downstream oxygen sensor. Using Socket (YA8875), remove
downstream oxygen sensor from exhaust pipe.
Installation
If installing original or used downstream oxygen sensor,
apply anti-seize compound on threads of downstream oxygen sensor. A
NEW downstream oxygen sensor should already be coated with anti-seize
compound. Install and tighten downstream oxygen sensor to
specification. See TORQUE SPECIFICATIONS. Install electrical
connector.
ENGINE COOLANT TEMPERATURE SENSOR
Removal & Installation (Dakota 2.5L)
1) Partially drain cooling system. Disconnect electrical
connector at engine coolant temperature sensor. Engine coolant
temperature sensor is located on side of thermostat housing and
contains a Tan/Black wire and a Black/Light Blue wire in the
electrical connector.
2) Remove engine coolant temperature sensor. To install,
reverse removal procedure. Tighten engine coolant temperature sensor
to specification. See TORQUE SPECIFICATIONS. Fill cooling system.
Removal (Dakota 3.9L, 5.2L & 5.9L, Durango & Ram Pickup 3.9L,
5.2L & 5.9L)
1) Partially drain cooling system. Engine coolant temperature
sensor is located on front of intake manifold, near inside of
generator and contains a Tan/Black wire and a Black/Light Blue wire in
the electrical connector.
2) Remove air cleaner if necessary for access to engine
coolant temperature sensor. On models equipped with A/C, go to next
step. On models not equipped with A/C, disconnect electrical connector
at engine coolant temperature sensor. Remove engine coolant
temperature sensor.
3) On A/C equipped models, electrical connector on engine
coolant temperature sensor may be difficult to reach. It may be
necessary to use a coat hanger and fabricate an "L" shaped tool about
8" (203 mm) long to disconnect electrical connector by placing hook
part of tool under electrical connector and pulling electrical
connector upward from engine coolant temperature sensor. Remove engine
coolant temperature sensor.
Installation
To install, reverse removal procedure. Tighten engine coolant
temperature sensor to specification. See TORQUE SPECIFICATIONS. Fill
cooling system.
Removal & Installation (Ram Pickup 8.0L)
1) Partially drain cooling system. Engine coolant temperature
sensor is located on front of intake manifold, near rear of generator
and contains a Tan/Black wire and a Black/Light Blue wire in the
electrical connector.
2) Disconnect electrical connector at engine coolant
temperature sensor. Remove engine coolant temperature sensor.
3) To install, reverse removal procedure. Tighten engine
coolant temperature sensor to specification. See TORQUE
SPECIFICATIONS. Fill cooling system.
Removal (Ram Van & Ram Wagon)

1) Partially drain cooling system. Engine coolant temperature
sensor is located on front of intake manifold, near inside of
generator and contains a Tan/Black wire and a Black/Light Blue wire in
the electrical connector.
2) On 3.9L, remove engine cover and air cleaner housing from
inside of vehicle for access to engine coolant temperature sensor. On
5.2L and 5.9L, engine coolant temperature sensor may be serviced from
front of vehicle without removing engine cover and air cleaner
housing.
3) On all models, disconnect electrical connector at engine
coolant temperature sensor. It may be necessary to use a coat hanger
and fabricate an "L" shaped tool about 8" (203 mm) long to disconnect
electrical connector by placing hook part of tool under electrical
connector and pulling electrical connector upward from engine coolant
temperature sensor. Remove engine coolant temperature sensor.
Installation
To install, reverse removal procedure. Tighten engine coolant
temperature sensor to specification. See TORQUE SPECIFICATIONS. Fill
cooling system.
FUEL LEVEL SENSOR
Removal & Installation
See FUEL LEVEL SENSOR under FUEL SYSTEM.
INTAKE AIR TEMPERATURE (IAT) SENSOR
NOTE: Intake air temperature sensor may also be referred to as
intake manifold air temperature sensor.
Removal & Installation (Dakota, Durango & Ram Pickup)
1) IAT sensor is screwed into the intake manifold. See Fig. 4
, 5 or 6. Remove air inlet duct or air cleaner assembly for access to
IAT sensor if necessary. Disconnect electrical connector at IAT
sensor. Remove IAT sensor from intake manifold.
2) To install, reverse removal procedure. Tighten IAT sensor
to specification. See TORQUE SPECIFICATIONS.
Removal & Installation (Ram Van & Ram Wagon)
1) IAT sensor is screwed into the intake manifold. See Fig. 5
. On 3.9L, remove engine cover and air cleaner housing from inside of
vehicle for access to IAT sensor. On 5.2L and 5.9L, IAT sensor may be
serviced from front of vehicle without removing engine cover and air
cleaner housing.
2) On all models, disconnect electrical connector at IAT
sensor. Remove IAT sensor from intake manifold. To install, reverse
removal procedure. Tighten IAT sensor to specification. See TORQUE
SPECIFICATIONS.
Fig. 4: Locating Intake Air Temperature (IAT) Sensor (Dakota 2.5L)
Courtesy of Chrysler Corp.

Removal & Installation (Dakota, Durango & Ram Pickup 2.5L,
3.9L, 5.2L & 5.9L)
1) MAP sensor is located near throttle body and contains a 3-
pin electrical connector with an L-shaped rubber hose connecting it to
the throttle body. See Fig. 7 or 8. Remove air inlet duct or air
cleaner assembly for access to MAP sensor if necessary.
2) Ensure area around MAP sensor is clean. Disconnect
electrical connector at MAP sensor. Remove MAP sensor retaining bolts.
Remove MAP sensor while disconnecting L-shaped rubber hose from
throttle body. Remove L-shaped rubber hose from MAP sensor.
3) To install, reverse removal procedure. Ensure L-shaped
rubber hose is properly installed on throttle body and MAP sensor.
Tighten MAP sensor retaining bolts to specification. See TORQUE
SPECIFICATIONS.
Removal & Installation (Ram Pickup 8.0L)
1) MAP sensor is located on upper side of intake manifold and
contains a 3-pin electrical connector. See Fig. 9. Disconnect
electrical connector at MAP sensor.
2) Ensure area around MAP sensor is clean. Remove MAP sensor
retaining bolts. Remove MAP sensor with rubber seal gasket from intake
manifold. Rubber seal gasket is part of the MAP sensor and is not
serviceable. Inspect rubber seal gasket for damage. Replace MAP sensor
with rubber seal gasket if gasket is defective.
3) To install, reverse removal procedure. Ensure seal area in
upper intake manifold is clean before installing MAP sensor. Lubricate
rubber seal gasket with engine oil before installing MAP sensor.
Tighten MAP sensor retaining bolts to specification. See TORQUE
SPECIFICATIONS.
Removal & Installation (Ram Van & Ram Wagon)
1) MAP sensor is located near throttle body and contains a 3-
pin electrical connector with an L-shaped rubber hose connecting it to
the throttle body. See Fig. 8. Remove engine cover and air cleaner
assembly for access to MAP sensor if necessary.
2) Ensure area around MAP sensor is clean. Disconnect
electrical connector at MAP sensor. Remove MAP sensor retaining bolts.
Remove MAP sensor while disconnecting L-shaped rubber hose from
throttle body. Remove L-shaped rubber hose from MAP sensor.
3) To install, reverse removal procedure. Ensure L-shaped
rubber hose is properly installed on throttle body and MAP sensor.
Tighten MAP sensor retaining bolts to specification. See TORQUE
SPECIFICATIONS.
Fig. 7: Locating Manifold Absolute Pressure (MAP) Sensor (Dakota
2.5L)
Courtesy of Chrysler Corp.