RAM 3500 Truck 4WD V10-8.0L VIN W (1997)
application.
18.
Loosely connect the pressure line "P" to the pressure port fitting "P" on the bypass assembly block.
19.
Loosely connect the radiator return line, "RR" to the "RR" port fitting, on the bypass assembly block.
NOTE:
DURING THE INSTALLATION OF THE "P" AND "RR" LINES, THE ORDER MAY BE REVERSED TO AID IN THE ASSEMBLY
PROCESS.
NOTE:
ON 5.2L ZJ MODELS, THE THROTTLE VALVE CABLE AND BRACKET MAY REQUIRE REMOVAL FOR BYPASS TUBE CLEARANCE.
ONCE THE TUBES ARE INSTALLED LOOSELY, INSTALL THE BRACKET AND THROTTLE VALVE CABLE. MAKE ANY
ADJUSTMENTS FOR CLEARANCE AND TIGHTEN THE BYPASS TUBES AND BRACKET ASSEMBLY.
20.
Make sure that the existing return line is properly re-attached to the hanger bracket and lay the new return line, "RR", beside it.
21.
Install the hose bracket (# 12 in Figure 1) required for the overhead line application. The bracket will replace the existing bracket at the starter
mount location. It may require slight modification to provide the best clearance from the exhaust system.
22.
Attach clamp (# 11 in Figure 1) and the rubber hose to the "RR" tube to determine the approximate rubber hose routing. For connection to the
existing return line, the line may be cut again to provide optimum line routing.
CAUTION:
WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE
PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE
EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM.
23.
Cut the rubber hose so that it has sufficient length to be attached to the existing return line.
24.
Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing return line.
25.
Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1).
26.
Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Make modifications as necessary to
provide the best routing.
27.
Disconnect the "RR" tube from the Bypass Block for access to the "P" port on the block assembly.
28.
Attach a clamp and the rubber hose to the "P" tube and determine the approximate rubber hose routing. For connection to the existing pressure
line, the line may be cut again to provide optimum line routing.
CAUTION:
WHEN ROUTING THE TUBING AND HOSE BE AWARE OF POTENTIAL MOVING COMPONENT INTERFERENCES, SUCH AS THE
PROPELLER SHAFT, SHIFT LINKAGE IN ALL POSITIONS, TV CABLE, TV RETURN SPRING, AND TV LINKAGE. BE AWARE OF THE
EXHAUST SYSTEM, ALL ROUTINGS SHOULD MAINTAIN AT LEAST ONE INCH OF CLEARANCE FROM THE EXHAUST SYSTEM.
29.
Cut the rubber hose so that it has sufficient length to be attached to the existing pressure line.
30.
Loosely connect a nut (# 7 in Figure 1), a compression sleeve (# 8 in Figure 1), and a hose fitting (# 10 in Figure 1) to the existing pressure line.
31.
Using a clamp (# 11 in Figure 1), install the rubber hose onto the hose fitting (# 10 in Figure 1).
32.
Evaluate the line routing to ensure moving components and exhaust will not interfere with the new lines. Use tie straps and rubber bumpers on the
hose to protect the hose from metal surfaces that may cause chaffing.
33.
Torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to 6.78 Nm (60 in. lbs.) on the
"P" line.
34.
Connect the "RR" ling and torque both clamps, the compression fitting (finger tight, then wrench tighten 1/2 turn), and the inverted flare nut to
6.78 Nm (60 in. lbs.) on the "P" line.
35.
Re-check to ensure that all connections have been securely tightened and there is sufficient clearance around the exhaust system.
36.
If applicable, connect the wire harness to the temperature sensor.
