1999 DODGE RAM Fuel pressure
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![DODGE RAM 1999 Service Repair Manual Limited Slip
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Differential Model 248 (4WD) 7.3 Pts. (3](/manual-img/12/56915/w960_56915-890.png "DODGE RAM 1999 Service Repair Manual Limited Slip
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Differential Model 248 (4WD) 7.3 Pts. (3")
Limited Slip
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Differential Model 248 (4WD) 7.3 Pts. (3.4L)
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Model 267 (2WD) 7 Pts. (3.3L)
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Model 267 (4WD) 7.8 Pts. (3.6L)
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Model 286 (2WD) 6.8 Pts. (3.2L)
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Model 286 (4WD) 10.1 Pts. (4.8L)
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Front Axle Model 216 6.8 Pts. (3.6L)
Lubricant
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Model 248 7.6 Pts. (3.6L)
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Transfer Case NV231 HD 2.5 Pts. (1.2L)
Fluid
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Power Take NV021 4.6 Pts. (2.1L)
Off Adapter
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Power Drained 2.7 Pts. (1.3L)
Steering
Fluid
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A/C Charge Capacity 32 Oz. (.9Kg)
Refrigerant
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Refrigerant A/C System Capacity 7.75 Oz. (230ML)
Oil
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Fuel Tank 119" & 139" Wheelbase Vehicles 26 Gal. (98L)
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All Others 35 Gal. (132L)
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1) - Capacities are recommended or calculated levels. Always use
dipstick (if available) to measure level.
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WHEEL & TIRE SPECIFICATIONS
TIRE REPLACEMENT
The tires on your new vehicle provide a balance of many
characteristics. They should be inspected regularly for wear and
correct inflation pressure. Chrysler strongly recommends that you use
tires equivalent to the originals in quality and performance when
replacement is needed. Failure to use equivalent replacement tires may
adversely affect the safety, handling and ride of your vehicle. We
recommend that you contact your original equipment tire dealer on any
questions you may have on tire specifications or capability.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE\
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Lug Nut Ft. Lbs. (N.m)
BR1500 (5 Stud Wheel) ........................... 95 (130)
BR2500 (8 Stud Wheel) ........................... 135 (180)
Page 895 of 1691
CAUTION: If fuel contamination due to fungi or other microorganisms is
suspected a fuel additive with a biocide may be used. Follow
the manufacturers dosage as recommended on product label. Use
biocides ONLY when necessary, excessive use can may cause
other fuel system problems.
DIESEL FUEL CONTAMINATION
WARNING: Diesel fuel system may be contaminated with fungi or other
microorganisms. Keep contaminated fuel away from open skin
cuts or sores to prevent skin irritation or infection.
DIESEL FUEL REQUIREMENTS
CAUTION: All diesel engines have been developed to take advantage of
the high energy content of No. 2 diesel fuel or No. 2
climatized-diesel fuels. It also operates on No. 1-diesel
fuels if temperatures are expected to be extended arctic
conditions -10
\bF (-23\bC).
WARNING: Do NOT use alcohol or gasoline as a fuel blending agent. They
can be unstable under certain conditions and hazardous or
explosive when mixed with diesel fuel.
ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
WARNING: Many solid state electrical components can be damaged by
static electricity (ESD). Some will display a warning label,
but many will not. Discharge personal static electricity by
touching a metal ground point on the vehicle prior to
servicing any ESD sensitive component.
ENGINE OIL
CAUTION: Never use non-detergent or straight mineral oil.
ENGINE OIL FILTER (CARTRIDGE TYPE)
CAUTION: Use of Mopar Oil Filter Cartridge (P/N 04746914) is
RECOMMENDED. The engine oil filter cartridge should be
changed at every engine oil change. Use the same type oil
that will be used in the engine.
FUEL SYSTEM SERVICE
WARNING: Relieve fuel system pressure prior to servicing any fuel
system component (fuel injection models).
HALOGEN BULBS
WARNING: Halogen bulbs contain pressurized gas which may explode if
overheated. DO NOT touch glass portion of bulb with bare
hands. Eye protection should be worn when handling or working
around halogen bulbs.
RADIATOR CAP
CAUTION: Always disconnect the fan motor when working near the
radiator fan. The fan is temperature controlled and could
start at any time even when the ignition key is in the OFF
position. DO NOT loosen or remove radiator cap when cooling
system is hot.
Page 898 of 1691
F1 - Not Used
F2 - 30 Amp (Lt. Green)
Blower Motor
CB1 - 30 Amp (Circuit Breaker)
Power Windows
CB2 - 30 Amp (Circuit Breaker)
Power Seats
1 - 20 Amp (Yellow)
Power Outlet
2 - Not Used
3 - Not Used
4 - Not Used
5 - 20 Amp (Yellow)
Cigar Lighter
6 - 20 Amp (Yellow)
Turn Signal Flasher
7 - 15 Amp (Lt. Blue)
Radio
8 - 20 Amp (Yellow)
Windshield Wipers
9 - 10 Amp (Red)
Fuel Pump Relay, A/C Compressor Clutch Relay
Automatic Shutdown Relay, Transmission Overdrive
Solenoid, EGR Solenoid, Powertrain Control Module (PCM)
Ignition Module
High Pressure Fuel Shut-Off Solenoid Relay (CNG Models Only)
EGR Solenoid (CNG Models Only)
10 - Not Used
Vehicle Speed Control
11 - 10 Amp (Red)
Buzzer, Overhead Console
12 - 15 Amp (Lt. Blue)
Airbag Diagnostic Module, Cluster, Message Center,
13 - 5 Amp (Tan)
Illumination
14 - 20 Amp (Yellow)
RWAL and ABS Module
15 - 15 Amp (Lt. Blue)
Automatic Day/Night Mirror, Back-up Lights,
Daytime Running Lamps
16 - 15 Amp (Lt. Blue)
Airbag Diagnostic Module
17 - 15 Amp (Lt. Blue)
Ignition Off Draw, Radio and Clock Memory
18 - 15 Amp (Lt. Blue)
Parking Lamps
19 - 20 Amp (Yellow)
Power Door Locks
20 - 15 Amp (Lt. Blue)
Stop Lamps
POWER DISTRIBUTION CENTER
Page 930 of 1691
FUEL LINE BLEEDING
NOTE: Fuel line bleeding is necessary if fuel injection pump is
replaced, fuel filter/water separator is not filled with
diesel fuel before installing or vehicle ran out off fuel.
Bleed high-pressure fuel lines if connections are loosened or
replaced. If engine has not been operated for an extended
time, bleed fuel lines before next initial engine start-up.
WARNING: DO NOT bleed fuel lines on a hot engine, as high exhaust
temperatures may cause a fire. Carefully bleed fuel lines, as
fuel is under extremely high pressure and could penetrate
skin. Use safety goggles and protective clothing when
bleeding fuel lines.
1) Loosen banjo bolt holding low-pressure fuel supply line to
side of fuel injection pump. Wrap a towel around banjo fitting to
catch fuel. Crank engine quickly and release key before engine starts.
This will operate fuel transfer pump for about 25 seconds.
2) If fuel is not present at fuel supply line after 25
seconds, turn ignition off. Repeat engine crank procedure until fuel
is present at fuel supply line. Tighten banjo bolt at fuel supply line
to specification. See TORQUE SPECIFICATIONS.
CAUTION: Ensure parking brake is applied and transmission is in
Neutral before bleeding fuel injection pump or high-pressure
fuel lines. DO NOT operate starter for more than 30 seconds
when bleeding fuel injection pump or high-pressure fuel
lines. Allow 2-minute intervals between starter operations.
3) To bleed air from fuel injection pump, ensure parking
brake is applied and transmission is in Neutral, as engine may start
when operating starter to bleed air from fuel injection pump. Operate
starter for 30 seconds to bleed any trapped air in fuel injection
pump.
4) To bleed high-pressure fuel lines, ensure parking brake is
applied and transmission is in Neutral, as engine may start when
operating starter to bleed high-pressure fuel lines. Loosen high-
pressure fuel line nut at fuel injector.
5) Operate starter until steady fuel flow exists at high-
pressure fuel line. Tighten high-pressure fuel line nut to
specification. See TORQUE SPECIFICATIONS. Start engine. Repeat
procedure on each high-pressure fuel line until engine operates
smoothly.
FUEL FILTER/WATER SEPARATOR & WATER-IN-FUEL SENSOR
NOTE: Vehicle also contains an in-tank fuel filter located on
bottom of fuel tank module. For servicing procedure, see FUEL
TANK MODULE & IN-TANK FUEL FILTER under FUEL SYSTEM.
NOTE: When fuel filter/water separator is being replaced,
manufacturer recommends cleaning the pre-filter. See FUEL
HEATER under FUEL SYSTEM for servicing of pre-filter.
Removal
1) Ensure engine is off. Place drain pan below drain tube at
fuel filter/water separator. See Fig. 3. Rotate handle on drain valve
forward, toward front of vehicle to DRAIN position. Drain valve is
located near top of fuel filter/water separator. See Fig. 3. Once fuel
is drained from fuel filter/water separator, rotate handle on drain
valve back to CLOSE position.
Page 931 of 1691
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.
Page 933 of 1691
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.
Page 934 of 1691
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.
Page 939 of 1691
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