1999 DODGE RAM drain bolt

2) Disconnect drain tube from drain valve. Disconnect
electrical connector for Water-In-Fuel (WIF) sensor at bottom of fuel
filter/water separator. See Fig. 3.
3) Support canister for fuel filter/water separator and
remove canister nut from top of filter mounting head. See Fig. 3.
Remove canister with fuel filter/water separator and seal ring from
filter mounting head. Remove fuel filter/water separator from
canister.
4) Remove "O" ring from top of shaft inside the canister.
Remove bolts and drain valve from canister (if necessary).
5) Check the 2 probes inside the canister on end of WIF
sensor for contamination. Clean probes if contaminated. If
contamination cannot be removed from the probes, replace WIF sensor.
If replacing WIF sensor, remove WIF sensor and "O" ring from canister.
6) Fuel heater is located inside fuel filter housing. Heater
mounting plate, heating element, temperature sensor, and wiring
harness are serviced as an assembly. Disconnect heater electrical
connector from engine wiring harness near upper rear part of filter.
7) Disconnect electrical connector at end of 2-wire harness
before attempting to pass harness through filter header. Remove clip
retaining wires to connector. Remove wires from connector. Remove 3
fuel heater screws. Press on heater sealing grommet to remove heater
from filter canister header. Pass wire through hole in filter header.
Remove fuel heater.
Installation
1) Ensure inside of canister is clean. Using NEW "O" ring,
install WIF sensor on canister (if removed). Tighten WIF sensor to
specification. See TORQUE SPECIFICATIONS.
2) Install drain valve on canister (if removed). Tighten
drain valve-to-canister bolts to specification. See TORQUE
SPECIFICATIONS.
3) Install NEW "O" ring on shaft inside canister. Coat "O"
ring with diesel fuel. Install NEW fuel filter/water separator and NEW
seal ring in canister. Coat seal ring with diesel fuel.
NOTE: Canister for fuel filter/water separator should be filled
with diesel fuel before installing. If canister cannot be
filled with diesel fuel, low-pressure fuel lines must be bled
after installation.
CAUTION: When installing canister on filter mounting head, ensure tab
areas on outside of canister align with tabs on filter
mounting head. This must be done to prevent damage to
canister and filter mounting head.
4) Fill canister for fuel filter/water separator with diesel
fuel. Install canister with fuel filter/water separator on filter
mounting head. Ensure canister fully engages with filter mounting head
and tab areas on outside of canister align with tabs on filter
mounting head.
5) Install and tighten canister nut to specification. See
TORQUE SPECIFICATIONS.
6) To install remaining components, reverse removal
procedure. If canister was not filled with diesel fuel, bleed low-
pressure fuel lines before starting engine. See FUEL LINE BLEEDING
under FUEL SYSTEM. Start engine and check for fuel leaks.
FUEL TANK MODULE & IN-TANK FUEL FILTER
NOTE: In-tank fuel filter is located on bottom of fuel tank module
which also contains the fuel gauge sending unit. Fuel tank
module is mounted on top of fuel tank.

Removal
1) 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).
2) Slightly lower fuel tank for access to fuel lines and
electrical connector at fuel tank module. Disconnect electrical
connector and fuel lines at fuel tank module. See Fig. 7. Use proper
procedure when disconnecting fuel lines. See FUEL LINE DISCONNECT
FITTINGS under FUEL SYSTEM.
NOTE: Information for servicing of in-tank fuel filter is not
available from manufacturer. If necessary to service in-tank
fuel filter, consult parts department to verify if filter may
be replace without replacing fuel tank module.
3) Note direction of fuel line connections on fuel tank
module for installation reference. Using Spanner Wrench (6856),
unscrew plastic fuel tank module lock nut from fuel tank. Remove fuel
tank module and gasket from fuel tank. Inspect in-tank fuel filter for
damage.
Installation
1) Using NEW gasket, install fuel tank module in fuel tank.
Install plastic fuel tank module lock nut finger tight. DO NOT tighten
plastic fuel tank module lock nut at this time.
2) Position fuel tank module so fuel line connections and
electric connection are facing toward driver's side of vehicle. This
must be done to prevent float on fuel gauge sending unit from
contacting fuel tank.
3) Once fuel tank module is properly positioned, tighten
plastic fuel tank module lock nut to specification. See TORQUE
SPECIFICATIONS.
4) Install fuel lines on fuel tank module using proper
procedure. See FUEL LINE DISCONNECT FITTINGS under FUEL SYSTEM.
Install electrical connector on fuel tank module. Reinstall fuel tank.
Tighten fuel tank strap nuts to specification. See TORQUE
SPECIFICATIONS. Reconnect negative battery cables.
Fig. 7: Locating Fuel Tank Module & Fuel Tank Rollover Valve
Courtesy of Chrysler Corp.
FUEL INJECTOR DRAIN LINE ASSEMBLY

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.

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

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








\









\









\









\









\









\









\







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.









\









\









\









\









\









\









\

pump to drain the fuel tank, go to next step.
2) Disconnect fuel line from fuel rail. See FUEL LINE AT FUEL
RAIL. Connect Fuel Hose (6541, 6539, 6631 or 6923) for proper engine
application at fuel line fitting on fuel rail. Place remaining end of
fuel hose in an approved gasoline container.
3) Connect scan tool to Data Link Connector (DLC). DLC is a
16-pin connector attached to bottom of driver's side of the instrument
panel, just straight above the accelerator pedal. Using scan tool
manufacturer's instructions, activate the fuel pump and pump fuel from
fuel tank. Once fuel tank is empty, remove scan tool. Reinstall fuel
line on fuel rail using proper procedure. Go to step 5).
4) Release fuel pressure from fuel system. See FUEL SYSTEM
PRESSURE RELEASE. Ensure negative battery cable is disconnected.
Remove fuel tank cap to release any residual fuel tank pressure.
5) Raise and support vehicle. Disconnect the small vent hose
from fill and vent hose fitting assembly at driver's side frame rail.
Fill and vent hose fitting assembly is permanently attached on fuel
tank. See Fig. 30.
6) If fuel tank was previously drained, go to next step. If
fuel tank was not previously drained, siphon fuel from fuel tank into
an approved gasoline container by installing siphon hose in small vent
hose fitting on fill and vent hose fitting assembly. Go to next step.
7) Disconnect large fill hose from fill and vent hose fitting
assembly at driver's side frame rail. Fill and vent hose fitting
assembly is permanently attached on fuel tank. See Fig. 30.
8) Support fuel tank with transmission jack. Remove fuel tank
strap retaining nuts from L-shaped bolts securing fuel tank straps on
frame rail. Remove fuel tank straps.
CAUTION: Fill and vent hose fitting assembly must be released from
plastic shield before lowering fuel tank. Use care when
lowering fuel tank as not to damage fill and vent hose
fitting assembly or the fuel tank.
9) Fill and vent hose fitting assembly is permanently
attached on fuel tank and is protected from the frame by a plastic
shield. See Fig. 30. Push retaining tabs inward to release fill and
vent hose fitting assembly from the plastic shield before lowering the
fuel tank. See Fig. 38.
Fig. 38: Releasing Retaining Tabs From Plastic Shield (Ram Van &
Ram Wagon)
Courtesy of Chrysler Corp.
10) Slightly lower fuel tank while guiding fill and vent hose

2.4L ........................................... 11.2 Qts. (10.6L)\
3.0L ........................................... 13.0 Qts. (12.3L)\
3.3L & 3.8L .................................... 13.2 Qts. (12.5L)\
Automatic Transaxle (Mopar ATF Plus Type 7176)
3-Speed
Drain & Refill .............................. (4) 4.0 Qts. (3.8L)
Dry Refill ...................................... 8.5 Qts. (8.0L)\
4-Speed
Drain & Refill .............................. ( 4) 4.0 Qts. (3.8L)
Dry Refill ...................................... 9.1 Qts. (8.6L)\
Overrunning Clutch
(Mopar ATF Plus Type 7176 - AWD Models) ...................... ( 5)
Power Steering Fluid ( 6) ............................ 1.7 Pts. (.8L)
Power Transfer Unit
(SAE 80W-90/API GL-5 - AWD Models) .............. 1.2 Qts. (1.14L\
)
Rear Differential
(SAE 80W-90/API GL-5 - AWD Models) ( 5) ....................... ( 7)
( 1) - Approximate quantity listed.
( 2) - Use an API energy conserving engine oil that is certified for
gasoline engines on all engines except 3.3L flex-fuel models.
On 3.3L flex-fuel models, use Mopar Flex-Fuel 5W-30 engine oil
or an equivalent that meets Chrysler Standard MS-9214. Proper
engine oil MUST BE used to prevent engine damage. The 3.3L
flex-fuel model may be referred to as Flex-Fuel Vehicle (FFV)
model and is used in all vehicles except California emission
vehicles. Flex-fuel model may be also referred to as an E85
application and may be identified by label attached to inside of
gasoline filler door.
( 3) - Quantity includes heater and coolant recovery tank. Add 2 qts.
(1.9L) if equipped with rear heater.
( 4) - Add this amount of fluid. Start engine and shift transaxle
through all gears and back to Park. Add additional fluid to
bring fluid level to 1/8" below the ADD mark on dipstick.
Recheck fluid level with transaxle at normal operating
temperature. Adjust fluid level so fluid level is within the
HOT range dipstick.
( 5) - An overrunning clutch is bolted on front of rear differential,
between torque tube for drive shaft and rear differential.
Overrunning clutch contains a separate reservoir from rear
differential. Ensure fluids are checked at appropriate
component, as different types of fluids are used. Fluid capacity
is not available from manufacturer.
( 6) - Use only Mopar power steering fluid. DO NOT use automatic
transmission fluid.
( 7) - Capacity is not available from manufacturer. Fill unit until
fluid level is even with bottom of filler plug hole.









\









\









\









\









\









\









\







FLUID CAPACITIES (DAKOTA)








\









\









\









\









\









\









\







Application ( 1) Quantity
Crankcase (Includes Filter) ( 2)
2.5L ............................................. 4.5 Qts. (4.3L)\
3.9L ............................................. 4.0 Qts. (3.8L)\
5.2L & 5.9L ...................................... 5.0 Qts. (4.7L)\
Cooling System (Includes Heater)
2.5L ............................................. 9.8 Qts. (9.3L)\
3.9L ........................................... 14.0 Qts. (13.2L)\
5.2L & 5.9L .................................... 14.3 Qts. (13.5L)\
Automatic Transmission
(Mopar ATF Plus Type 7176)