1999 DODGE RAM fuel filter

Removal
1) Remove nameplate located above rocker lever covers. Remove
fuel injector drain line-to-fuel injector banjo bolt and seal washer
from each fuel injector. Plug all fuel openings.
2) Remove fuel injector drain line assembly retaining clamp
at rear of intake manifold. Remove fuel injector drain line bolt with
seal washers at filter mounting head. See Fig. 3. Remove fuel injector
drain line assembly.
Installation
To install, reverse removal procedure using NEW seal washers.
Tighten bolts to specification. See TORQUE SPECIFICATIONS.
FUEL HEATER
Removal & Installation
Fuel heater is located in FUEL FILTER/WATER SEPARATOR &
WATER-IN-FUEL SENSOR. See FUEL FILTER/WATER SEPARATOR & WATER-IN-FUEL
SENSOR.
FUEL INJECTOR
Removal
1) Disconnect negative battery cables. Each fuel injector is
connected to each high-pressure fuel line with a steel connector line.
Steel connector is positioned into cylinder head and sealed with "O"
ring. See Fig. 8. If removing injector at cylinder No. 1 or No. 2,
remove intake manifold air heater assembly. If removing injector at
cylinder No. 5, remove engine lifting bracket. Ensure area around fuel
injector and high-pressure fuel line is clean. Disconnect high-
pressure fuel line at fuel injector. DO NOT bend any high-pressure
fuel line to gain access to fuel injector. It may be necessary to
remove high-pressure fuel lines from fuel injection pump for access to
fuel injector.
2) If removing high-pressure fuel lines from fuel injection
pump, mark high-pressure fuel line location for installation
reference. Remove valve cover. Thread Fuel Injector Connector Tube
Remover (8324) onto end of injector connector tube. Remove and discard\
old "O" ring from injector connector tube.
3) Remove fuel injector hold down clamp bolt at front end of
clamp. DO NOT loosen or remove shouldered bolt at rear of clamp.
Remove injector clamp by sliding it from shoulders on rear clamp bolt.
Thread rod from fuel injector remover into top of fuel injector.
Tighten nut to remove fuel injector from cylinder head. Remove and
discard "O" ring and copper sealing washer.
Fig. 8: Removing Fuel Injector
Courtesy of Chrysler Corp.
Installation
1) Clean fuel injector bore on cylinder head with wire brush.

Apply light coat of engine oil on NEW .060" (1.5 mm) thick Copper
sealing washer. Install NEW Copper sealing washer on spray tip of fuel
injector. Engine oil is used to aid holding sealing washer in place.
Install new "O" ring on fuel injector. Apply small amount of engine
oil to "O" ring.
2) Ensure fuel inlet hole on side of fuel injector is
positioned toward injector connector tube. Install injector into
cylinder head bore using care not to allow injector tip to touch sides
of bore. Press fuel injector into cylinder head with finger pressure
only. Install fuel injector hold down clamp into shouldered bolt while
aligning slot in top of injector into groove in bottom of clamp.
Tighten opposite clamp bolt to specification. See TORQUE
SPECIFICATIONS.
3) Apply small amount of clean engine oil to NEW "O" ring.
Install "O" ring to fuel injector connector tube. Using finger
pressure only, press injector connector tube into cylinder head.
Connect and tighten high pressure fuel lines to specification. See
TORQUE SPECIFICATIONS.
NOTE: Fuel line fitting torque is important. Mating surfaces will
not seal if fuel line fitting is under or over-torqued.
4) To install remaining components, reverse removal
procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Bleed high-pressure fuel lines. See FUEL LINE BLEEDING under FUEL
SYSTEM.
FUEL INJECTION PUMP
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. Clean fuel lines at
cylinder head and injection pump. Clean fuel injection pump and fuel
lines at side of pump. Disconnect 9-pin electrical connector at Fuel
Pump Control Module (FPCM). Place a rag around overflow valve to catch\
excess fuel. Remove overflow valve and disconnect fuel return line.
Remove banjo bolts and fuel supply line at side of injection pump and
top of fuel filter housing.
2) Remove all high pressure fuel lines, intake air tube,
accelerator pedal position sensor, air intake housing, engine oil
dipstick tube, wiring clips, electrical connectors at intake heaters,
and engine lifting bracket. Unscrew plastic access cap at front gear
cover. Remove injection pump gear-to-injection pump shaft nut and
washer.
3) Engine may be rotated by removing dust plug from
transmission adapter plate and installing Engine Barring Tool (Snap-On
SP371) in transmission adapter plate. See Fig. 9. Rotate engine until
keyway is at 12 o'clock position.

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.

1) Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE
under FUEL SYSTEM. Disconnect negative battery cable.
2) Ensure area around fuel line fitting on fuel line and fuel
rail is clean. Press sides of latch clip on fuel line fitting together
while rotating latch clip upward. See Fig. 26. Pull fuel line fitting
from fuel rail.
3) Inspect fuel line fitting for damage. If fuel line fitting
is damaged, entire fuel line assembly must be replaced.
4) To install, ensure fuel line fitting and fuel rail are
clean. Lubricate fuel line fitting and fuel rail with engine oil.
Install fuel line fitting on fuel rail.
5) Rotate latch clip downward so it snaps into position.
Ensure latch clip is fully snapped into position. If latch clip will
not snap into position, check for improper installation of fuel line
fitting on fuel rail. Pull on fuel line to ensure fuel line fitting is
properly locked on fuel rail. Reconnect negative battery cable. Start
engine and check for leaks.
Fig. 26: Disconnecting Fuel Line At Fuel Rail (Ram Van & Ram Wagon)
Courtesy of Chrysler Corp.
FUEL FILTER
Removal & Installation
Fuel filter is incorporated into the fuel pressure regulator.
A separate frame mounted fuel filter is not used. For servicing for
fuel filter/fuel pressure regulator, see FUEL FILTER/FUEL PRESSURE
REGULATOR.
FUEL FILTER/FUEL PRESSURE REGULATOR
Removal

1) Fuel filter/fuel pressure regulator is mounted in rubber
grommet on top of fuel pump module. See Figs. 27-30. Fuel pump module
is located on top of fuel tank.
2) Manufacturer recommends removing fuel tank for access to
fuel filter/fuel pressure regulator. See FUEL TANK. Ensure area around
fuel filter/fuel pressure regulator and fuel pump module is clean.
CAUTION: When removing fuel filter/fuel pressure regulator from fuel
tank, DO NOT pull fuel filter/fuel pressure regulator more
than 3.0" (76 mm) from fuel tank or plastic fuel line
attached to fuel filter/fuel pressure regulator may be
damaged.
3) Using twisting motion, pull fuel filter/fuel pressure
regulator from rubber grommet on fuel pump module. Ensure fuel
filter/fuel pressure regulator is not pulled more than 3.0" (76 mm)
from fuel tank or plastic fuel line attached to fuel filter/fuel
pressure regulator may be damaged.
4) Carefully cut plastic fuel line-to-fuel filter/fuel
pressure regulator retaining clamp. Use care not to damage plastic
fuel line. Remove retaining clamp. Remove plastic fuel line from fuel
filter/fuel pressure regulator.
Installation
1) Install plastic fuel line with NEW retaining clamp on fuel
filter/fuel pressure regulator. Rotate fuel filter/fuel pressure
regulator in plastic fuel line until fuel line fitting on side fuel
filter/fuel pressure regulator points proper direction. See
POSITIONING FUEL FILTER/FUEL PRESSURE REGULATOR table.
POSITIONING FUEL FILTER/FUEL PRESSURE REGULATOR









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Application Location Of Fuel Line Fitting
Dakota ............................. Toward Driver's Side Of Vehicle
Durango .................................... Toward Front Of Vehicle
Ram Pickup, Ram Van & Ram Wagon .... Toward Driver's Side Of Vehicle









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CAUTION: Ensure Crimping Pliers (C-4124) are used to crimp retaining
clamp for plastic fuel line. DO NOT use conventional side
cutters to crimp retaining clamp.
2) Using Crimping Pliers (C-4124), crimp retaining clamp for\
plastic fuel line. Ensure plastic fuel line is securely attached on
fuel filter/fuel pressure regulator.
3) To install remaining components, reverse removal
procedure. Ensure fuel filter/pressure regulator is installed in
rubber grommet on fuel pump module so fuel line fitting on side fuel
filter/fuel pressure regulator points toward proper direction before
installing fuel tank. See POSITIONING FUEL FILTER/FUEL PRESSURE
REGULATOR table. Reinstall fuel tank using proper procedure.

Removal & Installation
Fuel pressure regulator is incorporated with the fuel filter.
For servicing for fuel filter/fuel pressure regulator, see FUEL
FILTER/FUEL PRESSURE REGULATOR.
FUEL PUMP
Removal & Installation
Fuel pump is incorporated into the fuel pump module. See FUEL
PUMP MODULE.
FUEL PUMP INLET STRAINER
Removal & Installation
1) Fuel pump inlet strainer is mounted on fuel pump module.
See Fig. 31 . Remove fuel pump module. See FUEL PUMP MODULE.
2) Spread locking tabs on bottom of fuel pump module and
remove fuel pump inlet strainer from fuel pump module. See Fig. 31.
Remove "O" ring from end of fuel pump module if "O" ring was not
removed with fuel pump inlet strainer.
3) To install, reverse removal procedure. Ensure "O" ring is
properly seated when installing fuel pump inlet strainer. Reinstall
fuel pump module using proper procedure.
FUEL PUMP MODULE
Removal (Dakota)
1) Fuel pump module is located on top of fuel tank. See
Fig. 27 . Fuel tank must be removed for servicing of fuel pump module.
Remove fuel tank. See FUEL TANK.
2) Ensure area around fuel pump module is clean. Using Fuel
Pump Module Lock Nut Spanner Wrench (6856), remove fuel pump module
lock nut. See Fig. 32. Remove fuel pump module with rubber gasket from
fuel tank.
CAUTION: When fuel pump module is removed from fuel tank, rubber
gasket must be replaced. DO NOT reuse rubber gasket.
Installation
1) Ensure sealing area on fuel tank is clean. Using NEW
rubber gasket, install fuel pump module on fuel tank. DO NOT reuse
rubber gasket. Ensure rubber gasket remains in place.
NOTE: Fuel pump module must be properly positioned in fuel tank to
prevent float from contacting the fuel tank.
2) Rotate fuel pump module so alignment arrow on fuel pump
module is at 7 o'clock position and aligns with reference mark on fuel
tank. See Fig. 33. Install and hand tighten fuel pump module lock nut.
3) Note location of fuel pressure regulator on fuel pump
module. See Fig. 27. Ensure fuel filter/pressure regulator is
positioned on fuel pump module so fuel line fitting on side fuel
filter/fuel pressure regulator points toward driver's side of vehicle.
4) Hold fuel pump module in place while tightening fuel pump
module lock nut to specification. See TORQUE SPECIFICATIONS. Reinstall
fuel tank using proper procedure.

Fig. 28. Fuel tank must be removed for servicing of fuel pump module.
Remove fuel tank. See FUEL TANK under FUEL SYSTEM.
2) Ensure area around fuel pump module is clean. Rotate fuel
filter/pressure regulator so fuel line fitting on side fuel
filter/fuel pressure regulator points toward center of fuel pump
module.
3) Note location of metal fuel pump module lock ring and
locking fingers on the fuel tank. See Fig. 34. There are 6 locking
fingers molded into the plastic fuel tank.
4) Apply a small amount of engine oil on each locking finger
at the fuel pump module lock ring area. Engine oil will act as a
lubricant when removing fuel pump module lock ring.
5) Note location of lock tab on fuel pump module lock ring.
Pry lock tab backward while using a hammer and brass drift to tap fuel
pump module lock ring counterclockwise. Remove fuel pump module lock
ring, fuel pump module and rubber gasket from fuel tank.
CAUTION: When fuel pump module is removed from fuel tank, rubber
gasket must be replaced. DO NOT reuse rubber gasket.
Installation
1) Ensure sealing area on fuel tank is clean. Using NEW
rubber gasket, install fuel pump module on fuel tank. DO NOT reuse
rubber gasket. Ensure rubber gasket remains in place.
NOTE: Fuel pump module must be properly positioned in fuel tank to
prevent float from contacting the fuel tank.
2) Rotate fuel pump module so fuel pump is properly
positioned in the fuel tank. See Fig. 34. Apply a small amount of
engine oil on each locking finger at fuel pump module lock ring area.
Install fuel pump lock ring on fuel pump module.
3) Using a hammer and brass drift, tap fuel pump module lock
ring clockwise until the 6 locking fingers engage in fuel pump module
lock ring and lock tab engages notch on fuel pump module lock ring.
Ensure lock tab fully engages with notch on fuel pump module lock
ring. Reinstall fuel tank using proper procedure.
Fig. 34: Locating Fuel Pump Module Lock Ring, Locking Fingers &
Positioning Fuel Pump Module In Fuel Tank (Durango)
Courtesy of Chrysler Corp.
Removal (Ram Pickup)

1) Fuel pump module is located on top of fuel tank. See
Fig. 29. Fuel tank must be removed for servicing of fuel pump module.
Remove fuel tank. See FUEL TANK under FUEL SYSTEM.
2) Ensure area around fuel pump module is clean. Note
position of fuel pump module installation in fuel tank for
installation reference. Using Fuel Pump Module Lock Nut Spanner Wrench
(6856), remove fuel pump module lock nut. See Fig. 32. Remove fuel
pump module with rubber gasket from fuel tank.
CAUTION: When fuel pump module is removed from fuel tank, rubber
gasket must be replaced. DO NOT reuse rubber gasket.
Installation
1) Ensure sealing area on fuel tank is clean. Using NEW
rubber gasket, install fuel pump module on fuel tank. DO NOT reuse
rubber gasket. Ensure rubber gasket remains in place.
NOTE: Fuel pump module must be properly positioned in fuel tank to
prevent float from contacting the fuel tank.
2) Loosely install fuel pump module lock nut. Rotate fuel
pump module so electrical connector is pointing toward driver's side
of fuel tank. See Fig. 29.
3) Note location of fuel pressure regulator on fuel pump
module. See Fig. 29. Ensure fuel filter/pressure regulator is
positioned on fuel pump module so fuel line fitting on side fuel
filter/fuel pressure regulator points toward driver's side of fuel
tank.
4) Hold fuel pump module in place while tightening fuel pump
module lock nut to specification. See TORQUE SPECIFICATIONS. Reinstall
fuel tank using proper procedure.
Removal (Ram Van & Ram Wagon)
1) Fuel pump module is located on top of fuel tank. See
Fig. 30 . Fuel tank must be removed for servicing of fuel pump module.
Remove fuel tank. See FUEL TANK.
2) Ensure area around fuel pump module is clean. Using Fuel
Pump Module Lock Nut Spanner Wrench (6856), remove fuel pump module
lock nut. See Fig. 32. Remove fuel pump module with rubber gasket from
fuel tank.
CAUTION: When fuel pump module is removed from fuel tank, rubber
gasket must be replaced. DO NOT reuse rubber gasket.
Installation
1) Ensure sealing area on fuel tank is clean. Using NEW
rubber gasket, install fuel pump module on fuel tank. DO NOT reuse
rubber gasket. Ensure rubber gasket remains in place.
NOTE: Fuel pump module must be properly positioned in fuel tank to
prevent float from contacting the fuel tank.
2) Rotate fuel pump module so alignment mark on fuel pump
module aligns with reference mark on fuel tank. See Fig. 35. Install
and hand tighten fuel pump module lock nut.
3) Note location of fuel pressure regulator on fuel pump
module. See Fig. 35. Ensure fuel filter/pressure regulator is
positioned on fuel pump module so fuel line fitting on side fuel
filter/fuel pressure regulator points toward driver's side of vehicle.
4) Hold fuel pump module in place while tightening fuel pump
module lock nut to specification. See TORQUE SPECIFICATIONS. Reinstall
fuel tank using proper procedure.