Ram B1500, B2500, B3500, 1999-2003

Removal & Installation

Print

  1. The engine should be cold when performing this procedure.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Drain engine coolant to below sending unit level. A quart or so should be sufficient.
  6.  
  7. Disconnect the wiring from the temperature gauge sending unit.
  8.  
  9. Unscrew the old sending unit.
  10.  

To install:

  1. Coat the threads of the new unit with Teflon®tape or a temperature-resistant sealer.
  2.  
  3. Tighten the sensor to 11-15 ft lbs. (15-20 Nm).
  4.  
  5. Reconnect wiring. Start the engine and check operation. Check for leaks at operating temperature.

    Click image to see an enlarged view

    Fig. On 3.9L, 5.2L and 5.9L gas engines, the coolant temperature sensor is just behind the



    Click image to see an enlarged view

    Fig. Coolant temperature sensor position on the 4.7L engine



    Click image to see an enlarged view

    Fig. Coolant temperature sensor location-8.0L engine



    Click image to see an enlarged view

    Fig. Coolant temperature sensor-5.9L diesel engine

  6.  


CAUTION
Hot, pressurized coolant can cause injury by scalding. Cooling system must be partially drained before removing coolant temperature sensor.

The engine coolant temperature sensor is installed into a water jacket at front of intake manifold near rear of generator. If equipped with a 5.2L or 5.9L V-8 engine, removal/installation may be done from front of vehicle without removal of engine cover or air cleaner housing. If equipped with a 3.9L V-6 engine, the engine cover and air cleaner housing must be removed.

  1. Disconnect the negative battery cable.
  2.  
  3. For 3.9L engines:
    1. Remove engine cover.
    2.  
    3. Remove air cleaner housing.
    4.  

  4.  
  5. Place a small mirror above sensor connector.
  6.  
  7. Disconnect electrical connector from sensor. When removing connector from sensor, do not pull directly on wiring harness. Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). Place hook part of tool under connector for removal. The connector is snapped onto the sensor. It is not equipped with a lock type tab.
  8.  
  9. Partially drain cooling system.
  10.  
  11. Remove sensor from intake manifold.
  12.  

To install:

  1. Install sensor into intake manifold and tighten to 8 ft. lbs. (11 Nm).
  2.  
  3. Connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction.
  4.  
  5. Refill any the engine cooling system.
  6.  
  7. For 3.9L engines:
    1. Install air cleaner housing.
    2.  
    3. Install engine cover.
    4.  

  8.  
  9. Connect the negative battery cable.
  10.  

  1. The engine should be cold when performing this procedure.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Drain engine coolant to below sending unit level. A quart or so should be sufficient.
  6.  
  7. Disconnect the wiring from the temperature gauge sending unit.
  8.  
  9. Unscrew the old sending unit.
  10.  

To install:

  1. Coat the threads of the new unit with Teflon®tape or a temperature-resistant sealer.
  2.  
  3. Tighten the sensor to 11-15 ft lbs. (15-20 Nm).
  4.  
  5. Reconnect wiring. Start the engine and check operation. Check for leaks at operating temperature.
  6.  



Click image to see an enlarged view

Fig. Coolant temperature sensor-typical



Click image to see an enlarged view

Fig. Coolant temperature sensor on the 2.5L engine is in the thermostat housing



Click image to see an enlarged view

Fig. On 3.9L, 5.2L and 5.9L gas engines, the coolant temperature sensor is just behind the



Click image to see an enlarged view

Fig. Coolant temperature sensor position on the 4.7L engine



Click image to see an enlarged view

Fig. Coolant temperature sensor location-8.0L engine



Click image to see an enlarged view

Fig. Coolant temperature sensor-5.9L diesel engine

  1. Disconnect the negative battery cable.
  2.  


CAUTION
NEVER open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant.

  1. Drain the engine coolant below the level of the thermostat housing.
  2.  
  3. Remove the air cleaner assembly if necessary for access to the sensor.
  4.  
  5. Remove the connector from the sensor. Vehicles with air conditioning may benefit if you fabricate an L-shaped hook tool from a wire coat hanger about 8 in. (203mm) long. Use the hook for removal rather than pulling on the wiring harness.
  6.  
  7. Remove the sensor from the intake manifold.
  8.  

To install:

  1. Install the sensor in the manifold and tighten to 8 ft. lbs. (11 Nm).
  2.  
  3. Install the connector on the sensor. There is no polarity: the connector cannot be accidentally reversed.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Inspect for leaks.
  8.  
  9. Install the engine cover.
  10.  

 
label.common.footer.alt.autozoneLogo