Fuel system DODGE RAM 1500 1998 2.G Workshop Manual

WARNING: USE EXTREME CAUTION WHEN
INSPECTING FOR HIGH-PRESSURE FUEL LEAKS.
INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH
A SHEET OF CARDBOARD. HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
DIAGNOSIS AND TESTING - HIGH-PRESSURE
FUEL LINE LEAKS
High-pressure fuel line leaks can cause starting
problems and poor engine performance.
WARNING: DUE TO EXTREME FUEL PRESSURES
OF UP TO 160,000 kPa (23,206 PSI), USE EXTREME
CAUTION WHEN INSPECTING FOR HIGH-PRES-
SURE FUEL LEAKS. DO NOT GET YOUR HAND OR
A FINGER NEAR A SUSPECTED LEAK. INSPECT
FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET
OF CARDBOARD. HIGH FUEL INJECTION PRES-
SURE CAN CAUSE PERSONAL INJURY IF CON-
TACT IS MADE WITH THE SKIN.
Start the engine. Move the cardboard (Fig. 13) over
the suspected high-pressure fuel line leak, and check
for fuel spray onto the cardboard. If line is leaking,
retorque line. Replace damaged, restricted or leaking
high-pressure fuel lines with the correct replacement
line.
CAUTION: The high-pressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld high-pressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of high-pressure
fuel line is necessary.
REMOVAL
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and pos-
sible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Disconnect both negative battery cables from
both batteries. Cover and isolate ends of cables.(2) Thoroughly clean fuel lines at both ends.
(3) If removing fuel line at either #1 or #2 cylinder,
the intake manifold air heater elements must first be
removed from top of intake manifold. Refer to Intake
Air Heater Removal / Installation for procedures.
(4) If removing fuel line at #6 cylinder, a bracket
(Fig. 14) is located above fuel line connection at cyl-
inder head. Two bolts secure this bracket to rear of
cylinder head. The upper bolt hole is slotted. Loosen
(but do not remove) these 2 bracket bolts. Tilt
bracket down to gain access to #6 fuel line connec-
tion.
(5) Remove engine lift bracket (if necessary).
(6) Remove necessary insulated fuel line support
clamps (Fig. 15) and bracket bolts at intake manifold.
DO NOT remove insulators from fuel lines.
(7) Place shop towels around fuel lines at fuel rail
and injectors. If possible, do not allow fuel to drip
down side of engine.
CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE LINES ATTACHED TO A SEPA-
RATE FITTING (Fig. 16) , USE A BACK-UP WRENCH
ON FITTING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.
(8) Carefully remove each fuel line from engine.
Note position of each while removing.Do not bend
lines while removing.
Fig. 13 TYPICAL TEST FOR LEAKS USING
CARDBOARD
1 - HIGH-PRESSURE LINE
2 - CARDBOARD
3 - TYPICAL HIGH-PRESSURE FITTING
14 - 58 FUEL DELIVERY - DIESELDR
FUEL LINES (Continued)

INSTALLATION
All high-pressure fuel lines are of the same length
and inside diameter. Correct high-pressure fuel line
usage and installation is critical to smooth engine
operation.
CAUTION: Anytime a high-pressure line is removed
from the engine, its fuel connector nut at the cylin-
der head must first be retorqued. Refer to Torque
Specifications.
(1) Tighten fuel lines at high pressure injector con-
nector. Refer to Torque Specifications.
(2) Position fuel line support clamp(s) to fuel
line(s). Install clamp nuts/bolts and tighten finger
tight.
(3) Position proper fuel line to proper injector on
engine. Tighten fittings hand tight at both ends of
line.
(4) Tighten fuel lines at fuel rail. Refer to Torque
Specifications.
(5) Tighten clamp/support nuts and bolts. Refer to
Torque Specifications.
(6) Install engine lifting bracket and bolt. Refer to
Torque Specifications.
(7) If fuel line at either #1 or #2 cylinder has been
replaced, install intake manifold air heater elements
to top of intake manifold. Refer to Intake Air Heater
Removal / Installation for procedures.
(8) If fuel line at #6 cylinder has been replaced, tilt
metal bracket upward and tighten 2 bolts at rear of
cylinder head. Refer to Torque Specifications.
(9) Install remaining fuel line support clamps and
bracket bolts at intake manifold. Refer to Torque
Specifications.
(10) Connect both negative battery cables to both
batteries.
(11) Prime fuel system. Refer to Fuel System
Priming.
(12) Check lines/fittings for leaks.
FUEL PRESSURE SENSOR
DESCRIPTION
The fuel pressure sensor is mounted vertically near
the top/center of the fuel rail.
OPERATION
The fuel pressure sensor monitors actual high-
pressure within the fuel rail. An output signal from
this sensor (relating to fuel pressure) is sent to the
Engine Control Module (ECM).
REMOVAL
The fuel pressure sensor is mounted vertically near
the top/center of the fuel rail (Fig. 17).
(1) Disconnect electrical connector at sensor.
(2) Remove sensor from fuel rail.
(3) Inspect sensor sealing ring and its sealing sur-
face.
Fig. 17 FUEL PRESSURE SENSOR/FUEL PRES.
LIMIT. VALVE
1 - ELEC. CONNECTOR
2 - BANJO BOLT
3 - FUEL PRESSURE LIMITING VALVE
4 - FUEL PRESSURE SENSOR
5 - TOP OF INTAKE HEATER MANIFOLD
14 - 60 FUEL DELIVERY - DIESELDR
FUEL LINES (Continued)

INSTALLATION
(1) Inspect fuel pressure sensor sealing surface.
(2) Lubricate sensor threads with clean diesel fuel.
(3) Install sensor into fuel rail.
(4) To prevent leaks, sensormustbe tightened to
prescribed torque. Refer to Torque Specifications.
(5) Connect electrical connector to sensor.
(6) Start engine and check for fuel leaks.
FUEL PRESSURE LIMITING
VA LV E
DESCRIPTION
The fuel pressure limiting valve is located on the
top of the fuel rail.
OPERATION
Fuel pressure at the fuel rail is monitored by the
fuel rail pressure sensor. If fuel pressure becomes
excessive, the pressure limiting valve opens and
vents excess pressure into the fuel drain circuit.
REMOVAL
The fuel pressure limiting valve is located on the
top of the fuel rail (Fig. 18).
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and pos-
sible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Thoroughly clean area at pressure limiting
valve.
(2) Remove banjo bolt (Fig. 18) at banjo fitting.
(3) Remove pressure limiting valve from fuel rail.
INSTALLATION
(1) Be sure both top of manifold and limiting valve
are clean.
(2) Install valve. Refer to Torque Specifications.
(3) Assemble banjo bolt and new sealing washers
to limiting valve.
(4) Tighten banjo bolt. Refer to Torque Specifica-
tions.
Fig. 18 FUEL PRESSURE SENSOR/FUEL
PRESSURE LIMITING VALVE
1 - ELEC. CONNECTOR
2 - BANJO BOLT
3 - FUEL PRESSURE LIMITING VALVE
4 - FUEL PRESSURE SENSOR
5 - TOP OF INTAKE HEATER MANIFOLD
DRFUEL DELIVERY - DIESEL 14 - 61
FUEL PRESSURE SENSOR (Continued)

(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)

The torquing force of this threaded nut (fitting)
provides a sealing pressure between the fuel line con-
nector and the fuel injector.Retaining nut torque
is very critical.If the nut (fitting) is under torqued,
the mating surfaces will not seal and a high-pressure
fuel leak will result. If the fitting is over torqued, the
connector and injector will deform and also cause a
high-pressure fuel leak. This leak will be inside the
cylinder head and will not be visible. The result will
be a possible fuel injector miss-fire and low power, or
a no-start condition.
The fuel injectors use hole type nozzles. High-pres-
sure flows into the side of the injector, the ECM acti-
vates the solenoid causing the injector needle to lift
and fuel to be injected. The clearances in the nozzle
bore are extremely small and any dirt or contami-
nants will cause the injector to stick. Because of this,
it is very important to do a thorough cleaning of any
lines before opening up any fuel system component.
Always cover or cap any open fuel connections before
a fuel system repair is performed.
Each fuel injector connector tube contains an edge
filter that is designed to beak up small contaminants
before entering the fuel injector.The edge filters
are not a substitute for proper cleaning andcovering of all fuel system components during
repair.
The bottom of each fuel injector is sealed to the
cylinder head with a1.5mmthick copper shim (gas-
ket). The correct thickness shim must always be re-
installed after removing an injector.
Fuel pressure in the injector circuit decreases after
injection. The injector needle valve is immediately
closed and fuel flow into the combustion chamber is
stopped. Exhaust gases are prevented from entering
the injector nozzle by the needle valve.
REMOVAL
CAUTION: Refer to Cleaning Fuel System Parts.
Six individual, solenoid actuated high-pressure fuel
injectors are used (Fig. 14). The injectors are verti-
cally mounted into a bored hole in the top of the cyl-
inder head. This bored hole is located between the
intake/exhaust valves. High-pressure connectors (Fig.
15), mounted into the side of the cylinder head, con-
nect each fuel injector to each high-pressure fuel line.
(1) Disconnect both negative battery cables from
both batteries. Cover and isolate ends of cables.
(2) Remove breather assembly.
Fig. 15 HIGH-PRESSURE CONNECTOR
1 - HIGH-PRESSURE CONNECTOR (TO FUEL INJECTOR)
2 - O-RING
3 - CONNECTOR RETAINER4 - FUEL RAIL
5 - HIGH-PRESSURE FUEL LINES
6 - LOCATING PINS
DRFUEL INJECTION - DIESEL 14 - 75
FUEL INJECTOR (Continued)

(6) Install injector into cylinder head with male
connector port facing the intake manifold. Push down
on fuel injector mounting flange to engage o-ring and
seat injector.
(7) Tightening Sequence:
(a) Install fuel injector holdown clamp (mount-
ing flange) bolts.Do a preliminary tightening
of these bolts to 5 N´m (44 in. lbs.) torque.
This preliminary tightening insures the fuel
injector is seated and centered.
(b) After tightening, relieve bolt torque, but
leave both bolts threaded in place.
(c) Install high-pressure connector and retaining
nut. Do a preliminary tightening to 15 N´m (11 ft.
lbs.) torque.
(d) Alternately tighten injector holdown bolts to
10 N´m (89 in. lbs.) torque.
(e) Do a final tightening of the high-pressure
connector and retaining nut. Tighten to 50 N´m (37
ft. lbs.) torque.
(8) Connect injector solenoid wires and nuts to top
of injectors (Fig. 18). Tighten connector nuts to 1.25
N´m (11 in. lbs.) torque.Be very careful not to
overtighten these nuts as damage to fuel injec-
tor will occur.
(9) Install exhaust rocker arm assembly. Refer to
Engine.
(10) Set exhaust valve lash. Refer to Engine.
(11) Install high pressure fuel line. Refer to Torque
Specifications.Be sure to use a secondary
back-up wrench on the connector nut (fitting)
while torquing fuel line fitting.Refer to Fuel Line
Installation for additional information.
(12) Install valve cover. Refer to Engine.
(13) Install breather assembly.
(14) Connect negative battery cables to both bat-
teries.
FUEL INJECTOR RAIL
DESCRIPTION
The fuel injector rail is bolted to the top of the
intake manifold.
OPERATION
The fuel rail is used as a distribution device to
supply high-pressure fuel to the high-pressure fuel
lines.
REMOVAL
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and pos-
sible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Disconnect both negative battery cables at both
batteries. Isolate ends of both cables.
(2) Disconnect electrical connector at fuel pressure
sensor.
(3) Remove banjo bolt at fuel limiting valve.
(4) Disconnect necessary wiring harness retention
clips from intake manifold.
(5) Lift 2 rubber covers to gain access to positive
(+), intake heater cable nuts. Remove 2 nuts and
remove 2 cables from studs.
(6) Carefully remove 4 high-pressure fuel lines
from top of injector rail engine. Note position of each
line while removing.Do not bend lines while
removing.
CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE LINES ATTACHED TO A SEPA-
RATE FITTING, USE A BACK-UP WRENCH ON FIT-
TING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.
(7) Carefully remove 2 high-pressure fuel lines at
each end of injector rail. Note position of each line
while removing.Do not bend lines while remov-
ing.
(8) Remove fuel line connecting injector pump to
fuel rail.
(9) Remove 3 injector rail mounting bolts (Fig. 22).
(10) Remove rail from top of intake manifold.
INSTALLATION
(1) Clean any dirt/debris from top of intake mani-
fold and bottom of fuel rail.
(2) Position fuel rail to top of manifold and install
3 mounting bolts. Refer to Torque Specifications.
(3) Install all high-pressure lines to rail. Refer to
Fuel Lines for procedures.
(4) Reposition wiring harness to intake manifold
and install new tie wraps.
(5) Install and tighten fuel limiting valve banjo
bolt. Refer to Torque Specifications.
(6) Connect electrical connector to fuel pressure
sensor.
(7) Position 2 positive (+) cables to intake heater
studs. Install 2 nuts.
14 - 78 FUEL INJECTION - DIESELDR
FUEL INJECTOR (Continued)

STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-CoilsŸ, or equivalent. This repair con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-CoilŸ tap, or
equivalent, and installing a Heli-CoilŸ insert, or
equivalent, into the hole. This brings the hole back to
its original thread size.
Heli-CoilŸ, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
REMOVAL
NOTE: The overdrive unit can be removed and ser-
viced separately. It is not necessary to remove the
entire transmission assembly to perform overdrive
unit repairs.
(1) Disconnect battery negative cable.
(2) Raise vehicle.
(3) Remove the transfer case skid plate (Fig. 12), if
equipped.(4) Disconnect and lower or remove necessary
exhaust components.
(5) Remove engine-to-transmission struts.
(6) Remove starter motor. (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
(7) Disconnect and remove the crankshaft position
sensor. (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION/CRANKSHAFT POSITION SENSOR -
REMOVAL) Retain the sensor attaching bolts.
(8) If transmission is being removed for overhaul,
remove transmission oil pan, drain fluid and reinstall
pan.
(9) Remove torque converter access cover.
(10) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.
(11) Mark propeller shaft and axle yokes for
assembly alignment. Then disconnect and remove
propeller shaft. On4x4models, remove both propel-
ler shafts. (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(12) Disconnect wires from the transmission range
sensor and transmission solenoid connector.
(13) Disconnect gearshift cable (Fig. 13) from the
transmission.
Fig. 12 Transfer Case Skid Plate
1 - FRAME RAIL
2 - SKID PLATE
3 - BOLTS (6)
Fig. 13 Gearshift Cable At Transmission
1 - GEARSHIFT CABLE
2 - TRANSMISSION MANUAL LEVER
3 - CABLE SUPPORT BRACKET
21 - 158 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)

(13) Install bolts attaching converter housing to
engine.
(14) Install rear support.
(15) Install the rear transmission crossmember.
(16) Lower transmission onto crossmember and
install bolts attaching transmission mount to cross-
member.
(17) Remove engine support fixture.
(18) Install the transfer case, if equipped.
(19) Install crankshaft position sensor. (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/CRANKSHAFT
POSITION SENSOR - INSTALLATION)
(20) Connect gearshift cable (Fig. 64) and throttle
cable to transmission.
(21) Connect wires to the transmission range sen-
sor and transmission solenoid connector. Be sure the
transmission harnesses are properly routed.
CAUTION: It is essential that correct length bolts be
used to attach the converter to the driveplate. Bolts
that are too long will damage the clutch surface
inside the converter.(22) Install torque converter-to-driveplate bolts.
(23) Install converter housing access cover.
(24) Install starter motor and cooler line bracket.
(Refer to 8 - ELECTRICAL/STARTING/STARTER
MOTOR - INSTALLATION)
(25) Connect cooler lines (Fig. 65) to transmission.
(26) Install transmission fill tube. Install new seal
on tube before installation.
(27) Install any exhaust components previously
removed.
(28) Align and connect propeller shaft. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(29) Adjust gearshift cable and throttle valve
cable, if necessary.
(30) Install the transfer case skid plate, if
equipped.
(31) Lower vehicle.
(32) Fill transmission with MopartATF +4, Auto-
matic Transmission fluid.
Fig. 64 Gearshift Cable At Transmission
1 - GEARSHIFT CABLE
2 - TRANSMISSION MANUAL LEVER
3 - CABLE SUPPORT BRACKET
Fig. 65 Transmission Cooler Lines
1 - TRANSMISSION
2 - RADIATOR
3 - COOLER LINES
DRAUTOMATIC TRANSMISSION - 48RE 21 - 175
AUTOMATIC TRANSMISSION - 48RE (Continued)

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)

FRONT FENDER
REMOVAL
(1) Remove the antenna, if equipped. (Refer to 8 -
ELECTRICAL/AUDIO/ANTENNA BODY & CABLE -
REMOVAL)
(2) Remove the battery tray, if required. (Refer to 8
- ELECTRICAL/BATTERY SYSTEM/TRAY -
REMOVAL)
(3) Remove the cowl grille. (Refer to 23 - BODY/
EXTERIOR/COWL GRILLE - REMOVAL)
(4) Remove the headlamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - REMOVAL)
(5) Remove the wheelhouse splash shield. (Refer to
23 - BODY/EXTERIOR/FRONT WHEELHOUSE
SPLASH SHIELD - REMOVAL)
(6) Remove the inside and lower bolts. (Fig. 6)
(7) Remove the two bolts below the headlamp.
(8) Remove the hinge support bolt at the cowl.
(9) Remove the three bolts along the fender rail.
INSTALLATION
(1) Install the three bolts along the upper fender
rail and tighten to 9 N´m (80 in. lbs.).
(2) Install the upper hinge support bolt at the cowl
and tighten to 17 N´m (13 ft. lbs.).
(3) Install the two bolts below the headlamp and
tighten to 9 N´m (80 in. lbs.).(4) Install the inside and lower bolts and tighten
to 17 N´m (13 ft. lbs.).
(5) Check the fender positioning and adjust as
required by adding shims. (Refer to 23 - BODY/
BODY STRUCTURE/GAP AND FLUSH - SPECIFI-
CATIONS)
(6) Install the wheelhouse splash shield. (Refer to
23 - BODY/EXTERIOR/FRONT WHEELHOUSE
SPLASH SHIELD - INSTALLATION)
(7) Install the headlamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - INSTALLATION)
(8) Install the cowl grille. (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - INSTALLATION)
(9) Install the battery tray, if required. (Refer to 8
- ELECTRICAL/BATTERY SYSTEM/TRAY -
INSTALLATION)
(10) Install the antenna, if required. (Refer to 8 -
ELECTRICAL/AUDIO/ANTENNA BODY & CABLE -
INSTALLATION)
FUEL FILL DOOR
REMOVAL
(1) Open fill door and remove the bolts. (Fig. 7)
(2) Remove the door.
INSTALLATION
(1) Install the fuel fill door.
(2) Install the bolts and tighten to 9 N´m (80 in.
lbs.).
Fig. 6 FRONT FENDER
1 - HOOD HINGE SUPPORT BOLT (1)
2 - HOOD HINGE
3 - INNER BOLT (1)
4 - FRONT BOLTS (2)
5 - LOWER BOLT INSERT
6 - FENDER
7 - UPPER BOLTS (3)
Fig. 7 FUEL FILL DOOR
1 - FUEL FILL DOOR
2 - BOLTS (2)
DREXTERIOR 23 - 39