Fuel delivery DODGE RAM 1500 1998 2.G Manual PDF

(1) Drain fuel from fuel filter housing. Refer to
Fuel Filter/Water Separator - Removal. See Draining.
(2) Disconnect electrical connector (Fig. 23) from
fuel transfer pump.
(3) Disconnect fuel tank supply line from fuel
transfer pump extension line. This is done at discon-
nection point at inside of left inner frame rail (Fig.
24). Refer to quick-connect fittings for procedures.
(4) Remove 4 pump mounting bolts (hex-allen),
and remove pump from fuel filter housing.
(5) Confirm that transfer pump o-ring is also
removed from fuel filter housing.
INSTALLATION
(1) Install a new o-ring to fuel transfer pump.
(2) Lubricate o-ring and OD of transfer pump inlet
connector.
(3) Position fuel transfer pump onto fuel filter
housing.Do not use mounting bolts to draw
transfer pump to filter housing.
(4) Be sure pump is positioned flat to fuel filter
housing. Install mounting bolts and evenly tighten to
7 N´m (61 in. lbs.).
(5) Connect fuel line extension at fuel supply line.
(6) Connect electrical connector to pump.
(7)Prime System:Cycle key to actuate transfer
pump, or use DRB Scan Tool to actuate transfer
pump. Check for leaks.
(8) Operate engine and check for fuel leaks.
Fig. 23 FUEL TRANSFER (LIFT) PUMP
1 - FILTER HOUSING
2 - ELEC. CONNECTOR
3 - FUEL TRANSFER (LIFT) PUMP
4 - FUEL LINE EXTENTION
5 - MOUNTING BOLTS (4)
Fig. 24 TRANSFER PUMP FUEL LINE CONNECT
1 - LEFT INNER FRAME RAIL
2 - FUEL RETURN LINE
3 - FUEL SUPPLY LINE
4 - QUICK-CONNECT FITTING
DRFUEL DELIVERY - DIESEL 14 - 65
FUEL TRANSFER PUMP (Continued)

CASCADE OVERFLOW VALVE
DESCRIPTION
The cascade overflow valve is located on the top/
rear side of the fuel injection pump (Fig. 25).
OPERATION
When the fuel control actuator (FCA) is opened,
the maximum amount of fuel is being delivered to
the fuel injection pump. The cascade valve regulates
how much excess fuel is used for lubrication of the
injection pump, and is also used to route excess fuel
through the drain circuit and back into the fuel tank.
REMOVAL
REMOVAL/INSTALLATION
The cascade overflow valve is not serviced sepa-
rately.
WATER IN FUEL SENSOR
DESCRIPTION
The Water-In-Fuel (WIF) sensor is located on the
side of the fuel filter/water separator canister (Fig.
26).
OPERATION
The sensor sends an input to the Engine Control
Module (ECM) when it senses water in the fuel filter/
water separator. As the water level in the filter/sep-
arator increases, the resistance across the WIF
sensor decreases. This decrease in resistance is sent
as a signal to the ECM and compared to a high
water standard value. Once the value reaches 30 to
40 kilohms, the ECM will activate the water-in-fuel
warning lamp through CCD bus circuits. This all
takes place when the ignition key is initially put in
the ON position. The ECM continues to monitor the
input while the engine is running.
REMOVAL
The Water-In-Fuel (WIF) sensor is located at the
side of fuel filter/water separator canister. Refer to
Fuel Filter/Water Separator Removal/Installation for
WIF sensor removal/installation procedures.
Fig. 25 OVERFLOW VALVE
1 - BANJO BOLTS
2 - PUMP MOUNTING NUTS (3)
3 - FUEL INJECTION PUMP
4 - CASCADE OVERFLOW VALVE
Fig. 26 FILTER HOUSING
1 - FILTER HOUSING
2 - FUEL HEATER AND THERMOSTAT
3 - FUEL HEATER MOUNTING SCREWS
4 - FUEL HEATER ELEC. CONNECTOR
5 - WIF SENSOR
6 - WIF SENSOR ELEC. CONNECTOR
7 - DRAIN HOSE
8 - DRAIN VALVE MOUNTING SCREWS
9 - DRAIN VALVE
14 - 66 FUEL DELIVERY - DIESELDR

FUEL DRAIN CIRCUIT
OPERATION
The Fuel Drain Circuit incorporates several
sources of fuel return. Fuel travels from the fuel tank
to the fuel transfer pump and is forced through the
fuel filter. This fuel then travels into the fuel injec-
tion pump. It then goes to a fuel drain line and
returns back to the fuel tank.
The fuel that flows to the fuel pump is pressurized
by a gear pump and internally transferred to the fuel
injection pump. At this point the fuel is channeled
into two passages. One passage sends fuel to the
FCA (Fuel Control Actuator). The other passage
sends fuel to the cascade overflow valve. The over-
flow valve sends some fuel to a lubrication passage.
The rest of the fuel is sent to a drain passage which
connects to an external fuel line.Fuel that travels through the FCA is pressurized
by the fuel injection pump and sent through an
external high pressure fuel line to the fuel rail. At
the fuel rail, fuel is sent to the fuel injectors. If fuel
pressure in the fuel rail becomes excessive, the pres-
sure limiting valve opens and sends fuel through an
external fuel line.
At the fuel injector, fuel that is not injected is used
for lubrication of the fuel injectors. This fuel then
travels through an internal passage that is connected
to the rear of the cylinder head, an then into an
external fuel line. This line is connected to the vehi-
cles fuel return line, and returns excess fuel to the
fuel tank.
DRFUEL DELIVERY - DIESEL 14 - 67

INSTALLATION
(1) For the rear isolators install the rebound cush-
ions, washers, reinforcement plates and bolts. (Fig. 1)
(2) Install the remaining rebound cushions and
bolts.
(3) Tighten the bolts to 81 N´m (60 ft. lbs.).
CARGO BOX
REMOVAL
(1) Disconnect the fuel fill hose and vent hose.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL TANK - REMOVAL)
(2) Disconnect the tail lamp wire harness.
(3) Remove the cargo box bolts. (Fig. 2) or (Fig. 3)
(4) Remove the cargo box.
INSTALLATION
(1) Install the cargo box and install the bolts.
(2) Tighten the bolts to 108 N´m (80 ft. lbs.).
(3) Connect the fuel fill and vent hoses. (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK
- INSTALLATION)
(4) Connect the tail lamp wire harness.
Fig. 1 BODY ISOLATORS - TYPICAL
1 - CAB SILL
2 - ISOLATORS
3 - REBOUND CUSHION
4 - WASHER (REAR ISOLATOR ONLY)
5 - BOLTS
6 - REINFORCEMENT PLATE (REAR ISOLATOR ONLY)
Fig. 2 SHORT CARGO BOX
1 - CARGO BOX
2 - FRAME
3 - BOLTS (3 PER SIDE)
Fig. 3 LONG CARGO BOX
1 - CARGO BOX
2 - FRAME
3 - BOLTS (4 PER SIDE)
DREXTERIOR 23 - 37
BODY ISOLATORS (Continued)

SPECIFICATIONS
TORQUE - EVAP SYSTEM
DESCRIPTION N´m Ft. Lbs. In. Lbs.
EVAP Canister Mounting
Nuts11 -95
EVAP Canister Mounting
Bracket-to-Frame Bolts14 10125
Leak Detection Pump
Mounting Bolts11 - 9 5
Leak Detection Pump
Filter Mounting Bolt11 - 9 5
Fig. 1 FUEL DELIVERY COMPONENTS
1 - FUEL TANK 8 - LDP FRESH AIR FILTER
2 - CHECK VALVE 9 - LEAK DETECTION PUMP
3 - LIQUID EXPANSION CHAMBER 10 - EVAP CANISTERS (2)
4 - FUEL FILTER / FUEL PRESSURE REGULATOR 11 - FUEL TANK STRAPS (2)
5 - QUICK-CONNECT FITTING AND FUEL LINE (TO ENGINE) 12 - CHECK VALVE
6 - EVAP LINE CONNECTION 13 - FUEL PUMP MODULE LOCK RING
7 - LEAK DETECTION PUMP FRESH AIR LINE 14 - FUEL PUMP MODULE
DREVAPORATIVE EMISSIONS 25 - 11
EVAPORATIVE EMISSIONS (Continued)

FRONT SERVO - DESCRIPTION.........21-208
FRONT SERVO - DISASSEMBLY........21-209
FRONT SERVO - INSPECTION..........21-209
FRONT SERVO - OPERATION..........21-208
FRONT SKID PLATE - INSTALLATION.....13-23
FRONT SKID PLATE - REMOVAL.........13-23
FRONT SUSPENSION - DESCRIPTION,
GEAR - INDEPENDENT................19-17
FRONT SUSPENSION - INSTALLATION,
GEAR - INDEPENDENT................19-18
FRONT SUSPENSION - REMOVAL, GEAR
- INDEPENDENT.....................19-17
FRONT SUSPENSION, SPECIAL TOOLS....2-12
FRONT TOW HOOK ASSEMBLY -
INSTALLATION.......................13-23
FRONT TOW HOOK ASSEMBLY -
REMOVAL..........................13-23
FRONT WHEEL SPEED SENSOR -
DESCRIPTION........................5-47
FRONT WHEEL SPEED SENSOR -
INSTALLATION........................5-48
FRONT WHEEL SPEED SENSOR -
OPERATION..........................5-47
FRONT WHEEL SPEED SENSOR -
REMOVAL...........................5-48
FRONT WHEELHOUSE SPLASH SHIELD -
INSTALLATION.......................23-41
FRONT WHEELHOUSE SPLASH SHIELD -
REMOVAL..........................23-41
FUEL CONTROL ACTUATOR -
DESCRIPTION.......................14-74
FUEL CONTROL ACTUATOR -
OPERATION.........................14-74
FUEL CONTROL ACTUATOR - REMOVAL . . . 14-74
FUEL DELIVERY - GAS - DESCRIPTION....14-1
FUEL DELIVERY - GAS - OPERATION......14-2
FUEL DRAIN CIRCUIT - OPERATION......14-67
FUEL FILL DOOR - INSTALLATION.......23-39
FUEL FILL DOOR - REMOVAL...........23-39
FUEL FILLER CAP - DESCRIPTION.......25-13
FUEL FILLER CAP - OPERATION.........25-13
FUEL FILTER - STANDARD
PROCEDURES, WATER DRAINING AT.....14-47
FUEL FILTER / WATER SEPARATOR -
DESCRIPTION.......................14-50
FUEL FILTER / WATER SEPARATOR -
INSTALLATION.......................14-50
FUEL FILTER / WATER SEPARATOR -
OPERATION.........................14-50
FUEL FILTER / WATER SEPARATOR -
REMOVAL..........................14-50
FUEL FILTER/PRESSURE REGULATOR -
DESCRIPTION........................14-5
FUEL FILTER/PRESSURE REGULATOR -
OPERATION..........................14-6
FUEL GAUGE - DESCRIPTION...........8J-26
FUEL GAUGE - OPERATION.............8J-26
FUEL HEATER - DESCRIPTION..........14-51
FUEL HEATER - DIAGNOSIS AND
TESTING...........................14-52
FUEL HEATER - OPERATION............14-51
FUEL HEATER RELAY - DESCRIPTION....14-52
FUEL HEATER RELAY - INSTALLATION....14-53
FUEL HEATER RELAY - OPERATION......14-52
FUEL HEATER RELAY - REMOVAL........14-52
FUEL INDICATOR - DESCRIPTION, LOW . . . 8J-30
FUEL INDICATOR - OPERATION, LOW.....8J-30
FUEL INJECTION PUMP - DESCRIPTION . . 14-53
FUEL INJECTION PUMP - INSTALLATION . . 14-55
FUEL INJECTION PUMP - OPERATION....14-53
FUEL INJECTION PUMP - REMOVAL......14-54
FUEL INJECTION PUMP TIMING -
DIAGNOSIS AND TESTING.............14-53
FUEL INJECTOR - DESCRIPTION....14-26,14-74
FUEL INJECTOR - INSTALLATION........14-77
FUEL INJECTOR - OPERATION.....14-26,14-74
FUEL INJECTOR - REMOVAL............14-75
FUEL INJECTOR FIRING ORDER, DIESEL . . 14-48
FUEL INJECTOR RAIL - DESCRIPTION....14-78
FUEL INJECTOR RAIL - INSTALLATION....14-78
FUEL INJECTOR RAIL - OPERATION
......14-78
FUEL INJECTOR RAIL - REMOVAL
.......14-78
FUEL LEVEL SENDING UNIT / SENSOR -
DESCRIPTION
...................14-57,14-6
FUEL LEVEL SENDING UNIT / SENSOR -
INSTALLATION
........................14-7
FUEL LEVEL SENDING UNIT / SENSOR -
OPERATION
.....................14-57,14-6FUEL LEVEL SENDING UNIT / SENSOR -
REMOVAL...........................14-7
FUEL LINE LEAKS - DIAGNOSIS AND
TESTING, HIGH-PRESSURE.............14-58
FUEL LINES - DESCRIPTION........14-57,14-7
FUEL LINES - INSTALLATION...........14-60
FUEL LINES - OPERATION..............14-57
FUEL LINES - REMOVAL...............14-58
FUEL PRESSURE LIMITING VALVE -
DESCRIPTION.......................14-61
FUEL PRESSURE LIMITING VALVE -
INSTALLATION.......................14-61
FUEL PRESSURE LIMITING VALVE -
OPERATION.........................14-61
FUEL PRESSURE LIMITING VALVE -
REMOVAL..........................14-61
FUEL PRESSURE SENSOR -
DESCRIPTION.......................14-60
FUEL PRESSURE SENSOR -
INSTALLATION.......................14-61
FUEL PRESSURE SENSOR - OPERATION . . 14-60
FUEL PRESSURE SENSOR - REMOVAL....14-60
FUEL PUMP - DESCRIPTION............14-11
FUEL PUMP - OPERATION.............14-11
FUEL PUMP MODULE - DESCRIPTION....14-11
FUEL PUMP MODULE - INSTALLATION . . . 14-12
FUEL PUMP MODULE - OPERATION......14-11
FUEL PUMP MODULE - REMOVAL.......14-12
FUEL PUMP RELAY - DESCRIPTION......14-27
FUEL PUMP RELAY - INSTALLATION.....14-28
FUEL PUMP RELAY - OPERATION........14-27
FUEL PUMP RELAY - REMOVAL.........14-28
FUEL PUMP RELAYS - DIAGNOSIS AND
TESTING, ASD........................8I-5
FUEL RAIL - DESCRIPTION.............14-12
FUEL RAIL - INSTALLATION............14-15
FUEL RAIL - OPERATION...............14-12
FUEL RAIL - REMOVAL................14-13
FUEL REQUIREMENTS - DIESEL ENGINE
- DESCRIPTION........................0-1
FUEL SENSOR - DESCRIPTION, WATER
IN ................................14-66
FUEL SENSOR - OPERATION, WATER IN . . 14-66
FUEL SENSOR - REMOVAL, WATER IN....14-66
FUEL SYSTEM - DESCRIPTION, DIESEL . . . 14-45
FUEL SYSTEM - DIESEL ENGINE -
TORQUE............................14-48
FUEL SYSTEM - EXCEPT DIESEL -
TORQUE............................14-3
FUEL SYSTEM PARTS - STANDARD
PROCEDURES, CLEANING..............14-47
FUEL SYSTEM PRESSURE RELEASE -
STANDARD PROCEDURE................14-2
FUEL SYSTEM PRESSURE,
SPECIFICATIONS......................14-3
FUEL SYSTEM PRIMING - STANDARD
PROCEDURE........................14-47
FUEL SYSTEM, SPECIAL TOOLS..........14-5
FUEL SYSTEM, SPECIAL TOOLS -
DIESEL............................14-49
FUEL TANK - DESCRIPTION............14-17
FUEL TANK - OPERATION..............14-17
FUEL TANK MODULE - DESCRIPTION.....14-63
FUEL TANK MODULE - INSTALLATION....14-64
FUEL TANK MODULE - OPERATION......14-63
FUEL TANK MODULE - REMOVAL........14-63
FUEL TRANSFER PUMP - DESCRIPTION . . 14-64
FUEL TRANSFER PUMP - INSTALLATION . . 14-65
FUEL TRANSFER PUMP - OPERATION....14-64
FUEL TRANSFER PUMP - REMOVAL......14-64
FULL SIZE, SPARE WHEEL WITH
MATCHING TIRE - DESCRIPTION........22-15
FUNCTIONS - DESCRIPTION, CIRCUIT . . 8W-01-6
FUSE - DESCRIPTION, IOD...........8W-97-6
FUSE - INSTALLATION, IOD..........8W-97-7
FUSE - OPERATION, IOD.............8W-97-6
FUSE - REMOVAL, IOD..............8W-97-7
FUSES POWERING SEVERAL LOADS -
STANDARD PROCEDURE, TESTING
FOR A SHORT TO GROUND ON......8W-01-10
GAP AND FLUSH - SPECIFICATIONS......23-95
GAS ENGINE - DIAGNOSIS AND TESTING
. . 11-4
GAS ENGINE - INSTALLATION
...........19-26
GAS ENGINE - REMOVAL
..............19-25
GAS ENGINES - CLEANING, RADIATOR
FAN
................................7-34
GAS ENGINES - DESCRIPTION, COOLANT
RECOVERY CONTAINER
................7-33GAS ENGINES - INSPECTION, RADIATOR
FAN ................................7-34
GAS ENGINES - INSTALLATION,
COOLANT RECOVERY CONTAINER........7-33
GAS ENGINES - INSTALLATION,
RADIATOR FAN.......................7-34
GAS ENGINES - OPERATION, COOLANT
RECOVERY CONTAINER................7-33
GAS ENGINES - REMOVAL, COOLANT
RECOVERY CONTAINER................7-33
GAS ENGINES - REMOVAL, RADIATOR
FAN ................................7-33
GAS ENGINES - STANDARD
PROCEDURE, DRAINING COOLING
SYSTEM - ALL........................7-17
GAS ENGINES - STANDARD
PROCEDURE, REFILLING COOLING
SYSTEM - ALL........................7-18
GASKET - DIAGNOSIS AND TESTING,
CYLINDER HEAD......................9-21
GASKET FAILURE - DIAGNOSIS AND
TESTING, CYLINDER HEAD.............9-199
GASKET SELECTION - STANDARD
PROCEDURE, HEAD...................9-281
GASKET SURFACE PREPARATION -
STANDARD PROCEDURE, ENGINE........9-10
GASKETS AND SEALERS - STANDARD
PROCEDURE, FORM-IN-PLACE . . . 9-239,9-9,9-94
GAUGE - DESCRIPTION, ENGINE
TEMPERATURE......................8J-24
GAUGE - DESCRIPTION, FUEL...........8J-26
GAUGE - DESCRIPTION, OIL PRESSURE . . 8J-33
GAUGE - DESCRIPTION, VOLTAGE.......8J-42
GAUGE - OPERATION, ENGINE
TEMPERATURE......................8J-24
GAUGE - OPERATION, FUEL............8J-26
GAUGE - OPERATION, OIL PRESSURE....8J-33
GAUGE - OPERATION, VOLTAGE.........8J-43
GAUGES - DIAGNOSIS AND TESTING,
PRESSURE..........................22-7
GAUGES INDICATOR - DESCRIPTION,
CHECK.............................8J-21
GAUGES INDICATOR - OPERATION,
CHECK.............................8J-21
GEAR - DESCRIPTION, CRANKSHAFT.....9-273
GEAR - INDEPENDENT FRONT
SUSPENSION - DESCRIPTION...........19-17
GEAR - INDEPENDENT FRONT
SUSPENSION - INSTALLATION..........19-18
GEAR - INDEPENDENT FRONT
SUSPENSION - REMOVAL..............19-17
GEAR - INSTALLATION................9-273
GEAR - INSTALLATION, PINION
GEAR/RING......................3-51,3-77
GEAR - LINK/COIL - DESCRIPTION.......19-20
GEAR - LINK/COIL - INSTALLATION......19-21
GEAR - LINK/COIL - OPERATION........19-20
GEAR - LINK/COIL - REMOVAL..........19-20
GEAR - REMOVAL....................9-273
GEAR - REMOVAL, PINION GEAR/RING....3-49,
3-75
GEAR HOUSING - INSTALLATION........9-300
GEAR HOUSING - REMOVAL............9-299
GEAR HOUSING COVER - INSTALLATION . . 9-301
GEAR HOUSING COVER - REMOVAL
.....9-301
GEAR INPUT SHAFT SEAL -
INSTALLATION, STEERING
.............19-29
GEAR INPUT SHAFT SEAL - REMOVAL,
STEERING
..........................19-27
GEAR SELECTOR INDICATOR -
DESCRIPTION
.......................8J-27
GEAR SELECTOR INDICATOR -
OPERATION
.........................8J-27
GEAR SHIFT LEVER - INSTALLATION
.....19-12
GEAR SHIFT LEVER - REMOVAL
.........19-12
GEAR, SPECIAL TOOLS - POWER
STEERING
..........................19-23
GEAR, SPECIFICATIONS - POWER
STEERING
..........................19-22
GEAR TO COOLER - INSTALLATION,
RETURN HOSE
.................19-44,19-45
GEAR TO COOLER - REMOVAL, RETURN
HOSE
.........................19-44,19-45
GEAR/RING GEAR - INSTALLATION,
PINION
.........................3-51,3-77
GEAR/RING GEAR - REMOVAL, PINION
....3-49,
3-75
14 INDEXDR
Description Group-Page Description Group-Page Description Group-Page