torque DODGE RAM 1500 1998 2.G Workshop Manual

INSTALLATION
3.7L V-6
The Throttle Position Sensor (TPS) is mounted to
the throttle body (Fig. 37).
The throttle shaft end of throttle body slides into a
socket in TPS (Fig. 40). The TPS must be installed so
that it can be rotated a few degrees. (If sensor will
not rotate, install sensor with throttle shaft on other
side of socket tangs). The TPS will be under slight
tension when rotated.
(1) Install TPS and retaining screws.
(2) Tighten screws to 7 N´m (60 in. lbs.) torque.
(3) Connect TPS electrical connector to TPS.
(4) Manually operate throttle (by hand) to check
for any TPS binding before starting engine.
(5) Install air cleaner tube to throttle body.
4.7L V-8
The throttle shaft end of throttle body slides into a
socket in TPS (Fig. 41). The TPS must be installed so
that it can be rotated a few degrees. If sensor will
not rotate, install sensor with throttle shaft on other
side of socket tangs. The TPS will be under slight
tension when rotated.
(1) Install TPS and two retaining bolts.
(2) Tighten bolts to 7 N´m (60 in. lbs.) torque.
(3) Manually operate throttle control lever by hand
to check for any binding of TPS.
(4) Connect TPS electrical connector to TPS.
(5) Install air duct/air box to throttle body.
Fig. 40 TPS INSTALLATION - 3.7L
1 - THROTTLE BODY
2 - TPS
3 - THROTTLE BODY SHAFT
4 - SOCKET LOCATING TANGS
Fig. 41 TPS INSTALLATION - 4.7L
1 - THROTTLE BODY
2 - LOCATING TANGS
3 - THROTTLE POSITION SENSOR
4 - SOCKET
5 - THROTTLE SHAFT
DRFUEL INJECTION - GAS 14 - 43
THROTTLE POSITION SENSOR (Continued)

FUEL DELIVERY - DIESEL
TABLE OF CONTENTS
page page
FUEL DELIVERY - DIESEL
DESCRIPTION - DIESEL FUEL SYSTEM.....45
STANDARD PROCEDURE
STANDARD PROCEDURES - WATER
DRAINING AT FUEL FILTER..............47
STANDARD PROCEDURES - CLEANING
FUEL SYSTEM PARTS.................47
STANDARD PROCEDURE - FUEL SYSTEM
PRIMING............................47
SPECIFICATIONS
FUEL INJECTOR FIRING ORDER - DIESEL . 48
TORQUE - FUEL SYSTEM - DIESEL
ENGINE.............................48
SPECIAL TOOLS
DIESEL FUEL SYSTEM.................49
FUEL FILTER / WATER SEPARATOR
DESCRIPTION.........................50
OPERATION...........................50
REMOVAL.............................50
INSTALLATION.........................50
FUEL HEATER
DESCRIPTION.........................51
OPERATION...........................51
DIAGNOSIS AND TESTING - FUEL HEATER . . . 52
REMOVAL
REMOVAL/INSTALLATION...............52
FUEL HEATER RELAY
DESCRIPTION.........................52
OPERATION...........................52
REMOVAL.............................52
INSTALLATION.........................53
FUEL INJECTION PUMP
DESCRIPTION.........................53
OPERATION...........................53
DIAGNOSIS AND TESTING - FUEL INJECTION
PUMP TIMING........................53
REMOVAL.............................54
INSTALLATION.........................55
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION.........................57
OPERATION...........................57
REMOVAL
REMOVAL/INSTALLATION...............57FUEL LINES
DESCRIPTION.........................57
OPERATION...........................57
DIAGNOSIS AND TESTING - HIGH-
PRESSURE FUEL LINE LEAKS...........58
REMOVAL.............................58
INSTALLATION.........................60
FUEL PRESSURE SENSOR
DESCRIPTION.........................60
OPERATION...........................60
REMOVAL.............................60
INSTALLATION.........................61
FUEL PRESSURE LIMITING VALVE
DESCRIPTION.........................61
OPERATION...........................61
REMOVAL.............................61
INSTALLATION.........................61
FUEL TANK
DESCRIPTION - DIESEL..................62
REMOVAL - DIESEL.....................62
INSTALLATION - DIESEL.................62
FUEL TANK MODULE
DESCRIPTION.........................63
OPERATION...........................63
REMOVAL.............................63
INSTALLATION.........................64
FUEL TRANSFER PUMP
DESCRIPTION.........................64
OPERATION...........................64
REMOVAL.............................64
INSTALLATION.........................65
CASCADE OVERFLOW VALVE
DESCRIPTION.........................66
OPERATION...........................66
REMOVAL
REMOVAL/INSTALLATION...............66
WATER IN FUEL SENSOR
DESCRIPTION.........................66
OPERATION...........................66
REMOVAL.............................66
FUEL DRAIN CIRCUIT
OPERATION...........................67
14 - 44 FUEL DELIVERY - DIESELDR

SPECIFICATIONS
FUEL INJECTOR FIRING ORDER - DIESEL
1±5±3±6±2±4
TORQUE - FUEL SYSTEM - DIESEL ENGINE
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Accelerator Pedal Bracket Mounting 12 - 105
Accelerator Pedal Position Sensor
Bracket-to-Battery Tray Bolts3-30
Crankshaft Position Sensor 9 80
Camshaft Position Sensor 9 - 80
Engine Coolant Temperature Sensor 18 15 160
Rear Engine Lift Bracket Bolts 77 56 -
Fuel Connector Nut at Cylinder Head 50 37 -
Fuel Filler Hose Clamp at Tank 3 - 30
Fuel Filler Housing-to-Body Screws 2 - 17
Fuel Filter Lid 34 25 -
Fuel Filter Drain Valve Screws 1.5 - 14
Fuel Heater Element Screws 1.5 - 14
Fuel Pump Module Lock Ring 54 40 -
Fuel Line Banjo Fitting Bolts 24 18 -
Fuel Line Fittings (High-Pressure - Pump
to Rail)37 27 -
Fuel Line Fittings (High-Pressure -
Cylinder head to Rail)30 22 -
Bracket Over #6 Fuel Line (Bolts) 43 32 -
Fuel Injector Solenoid Nuts 1.25 - 11
Fuel Injection Pump-to-Gear Shaft Nut 105 77 -
Fuel Injection Pump Mounting Nuts 24 18 -
Fuel Line Support Clamps (High-
Pressure)24 18 -
Fuel Pressure Sensor 70 52 -
Fuel Pressure Limiting Valve (Banjo Bolt) 24 17 -
Fuel Pressure Limiting Valve (In Fuel
Rail)70 52 -
Fuel Rail Mounting Bolts 24 18 200
Fuel Tank Mounting Straps 41 30 -
Map Sensor Mounting Screws 1 - 9
ECM-to-Engine Bracket Mounting Bolts 24 18 -
ECM Electrical Harness Connector 3 - 27
Water-In-Fuel Sensor 4.5 - 39
14 - 48 FUEL DELIVERY - DIESELDR
FUEL DELIVERY - DIESEL (Continued)

(b) Install new o-ring to canister lid and lubri-
cate o-ring with clean engine oil.
(c) Position new element to canister lid. Place
this assembly into canister by rotating clockwise.
(d) Tighten cap to 34 N´m (25 ft. lbs.) torque. Do
not overtighten cap.
(3)Water-In-Fuel (WIF) Sensor:
(a) Install new o-ring seal to WIF sensor.
(b) Apply a light film of clean oil to o-ring seal.
(c) Install sensor into housing.
(d) Tighten sensor to 2.5 N´m (25 in. lbs.) torque.
(e) Connect electrical connector to WIF sensor.
(4)Fuel Heater Element:
(a) Install fuel heater into fuel filter housing.
(b) Install fuel heater thermostat into fuel filter
housing.
(c) Install fuel heater mounting screws and
tighten to 1-1.5 N´m (13 in. lbs.) torque.
(d) Connect electrical connector to fuel heater
thermostat.
(e) Install new filter cover O-ring onto fuel filter
housing cover and lubricate with clean engine oil.
(f) Tighten fuel filter housing cover (lid) to 34
N´m (25 ft. lbs.).
(5)Drain Valve:
(a) Install 2 new o-rings to valve and filter hous-
ing.
(b) Lubricate with silicon grease.
(c) Install fuel drain valve.
(d) Install 4 mounting screws and tighten to
1±1.5 N´m (8±13 in. lbs.) torque.
(e) Connect drain hose to drain valve.
(6) Start engine and check for leaks.
FUEL HEATER
DESCRIPTION
The fuel heater assembly is located on the side of
the fuel filter housing (Fig. 3).
The heater/element assembly is equipped with a
temperature sensor (thermostat) that senses fuel
temperature. This sensor is attached to the fuel heat-
er/element assembly.
OPERATION
The fuel heater is used to prevent diesel fuel from
waxing during cold weather operation.
When the temperature is below 45  8 degrees F,
the temperature sensor allows current to flow to the
heater element warming the fuel. When the temper-
ature is above 75  8 degrees F, the sensor stops cur-
rent flow to the heater element.
Battery voltage to operate the fuel heater element
is supplied from the ignition switch and through the
fuel heater relay. Also refer to Fuel Heater Relay.
Fig. 3 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
Fig. 4 FILTER COVER (LID)
1 - FILTER COVER
2 - ATTACH SOCKET HERE
DRFUEL DELIVERY - DIESEL 14 - 51
FUEL FILTER / WATER SEPARATOR (Continued)

This will ensure proper gear-to-shaft tighten-
ing.
(5) Clean pump gear and pump shaft at machined
tapers with an evaporative type cleaner such as
brake cleaner.
(6) Position injection pump to mounting flange on
gear housing while aligning injection pump shaft
through back of injection pump gear.
(7) After pump is positioned flat to mounting
flange, install 3 pump mounting nuts and tighten
finger tight only.Do not attempt a final tightening
at this time.Do not attempt to tighten (pull)
pump to gear housing using mounting nuts.
Damage to pump or gear cover may occur. The
pump must be positioned flat to its mounting
flange before attempting to tighten 3 mounting
nuts.
(8) To prevent damage or cracking of components,
install and tighten nuts in the following sequence:
(a) Install injection pump shaft washer and nut
to pump shaft. Tighten nutfinger tight only.
(b) Do preliminary (light) tightening of injection
pump shaft nut.
(c) Tighten 3 injection pump mounting nuts to
24 N´m (18 ft. lbs.).(d) Do a final tightening of pump shaft nut to
105 N´m (77 ft. lbs.).
(9) Install drive gear access cover (plate) using a
3/8º drive ratchet. Plate is threaded to timing gear
cover. Tighten to 8 N´m (71 in. lbs.) torque.
(10) Install fuel line (injection pump-to-pressure
limiting valve). Tighten bolts to 24 N´m (18 ft. lbs.)
torque.
(11) Install fuel line (injection pump-to-fuel rail).
(a) Tighten fitting at fuel pump to 37 N´m (27 ft.
lbs.) torque. Use a back-up wrench.
(b) Tighten fitting at fuel rail to 37 N´m (27 ft.
lbs.) torque.
(12) Install fuel line (injection pump-to-fuel filter
housing). Tighten to 24 N´m (18 ft. lbs.) torque.
(13) Connect Fuel Control Actuator (FCA) electri-
cal connector to rear of injection pump.
(14) Install intake manifold air intake tube (above
injection pump). Tighten clamps.
(15) Install accessory drive belt.
(16) Install cooling fan shroud.
(17) Install cooling fan assembly.
(18) Connect both negative battery cables to both
batteries.
(19) Check system for fuel or engine oil leaks.
Fig. 12 FUEL INJECTION PUMP REMOVAL/INSTALLATION
1 - PUMP DRIVE GEAR NUT
2 - WASHER
3 - PUMP DRIVE GEAR
4 - RUBBER O-RING
5 - FUEL INJECTION PUMP6 - PUMP MOUNTING NUTS (3)
7 - PUMP MOUNTING STUDS (3)
8 - O-RING MACHINED GROOVE
9 - FRONT TIMING GEAR HOUSING
14 - 56 FUEL DELIVERY - DIESELDR
FUEL INJECTION PUMP (Continued)

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)

FUEL TANK
DESCRIPTION - DIESEL
The fuel tank is similar to the tank used with gas-
oline powered models. The tank is equipped with a
separate fuel return line and a different fuel tank
module for diesel powered models. A fuel tank
mounted, electric fuel pump is not used with diesel
powered models. Refer to Fuel Tank Module for addi-
tional information.
REMOVAL - DIESEL
Fuel Tank Draining
Due to a one-way check valve installed into the
fuel fill opening fitting at the tank, the tank cannot
be drained conventionally at the fill cap.
(1) Raise vehicle.
(2) If vehicle is equipped with 4 doors and a 6 foot
(short) box, remove left-rear tire/wheel.
(3) Thoroughly clean area at top of fuel tank
around fuel tank module.
(4) Remove rubber cap from auxiliary fitting on
top of tank module (Fig. 19).
(5) Drain fuel tank by attaching drain hose from
an approved draining station to auxiliary fitting on
top of tank module (Fig. 19).
Tank Removal
(1) Loosen clamp and disconnect rubber fuel fill
hose at tank.
(2) Support tank with a hydraulic jack.
(3) Remove 2 fuel tank strap nuts (Fig. 20) and
remove both tank support straps.
(4) Carefully lower tank a few inches and discon-
nect fuel pump module electrical connector (Fig. 19)
at top of tank. To disconnect electrical connector:
Push upward on red colored tab to unlock. Push on
black colored tab while removing connector.
(5) Disconnect fuel supply and return lines at fuel
tank module (Fig. 19). Refer to Quick-Connect Fit-
tings for procedures.
(6) Continue to lower tank for removal.
(7) If fuel tank is to be replaced, remove fuel tank
module from tank. Refer to Fuel Tank Module
Removal/Installation procedures.INSTALLATION - DIESEL
(1) If fuel tank is to be replaced, install fuel tank
module into tank. Refer to Fuel Tank Module Remov-
al/Installation procedures.
(2) Position fuel tank to hydraulic jack.
(3) Raise tank until positioned near body.
(4) Connect fuel tank module electrical connector
at top of tank.
(5) Connect fuel supply and return lines to tank
module.
(6) Continue raising tank until positioned snug to
body.
(7) Install and position both tank support straps.
Install 2 fuel tank strap nuts and tighten.Tighten
rear strap nut first.Refer to Torque Specifications.
(8) Remove hydraulic jack.
(9) Connect rubber fill hose to fuel fill tube and
tighten clamp.
(10) Install tire / wheel (if necessary).
(11) Lower vehicle.
(12) Fill fuel tank with fuel.
(13) Start engine and check for fuel leaks near top
of module.
Fig. 19 FUEL TANK MODULE - DIESEL
1 - TOP OF FUEL TANK
2 - AUX. FITTING
3 - ELEC. CONNECTOR
4 - FUEL TANK MODULE (TOP)
5 - LOCKNUT
6 - FUEL SUPPLY LINE
7 - FUEL RETURN LINE
14 - 62 FUEL DELIVERY - DIESELDR

INSTALLATION
CAUTION: Whenever the fuel tank module is ser-
viced, the rubber gasket must be replaced.
(1) Thoroughly clean locknut and locknut threads
at top of tank.(2) Using new gasket, carefully position fuel tank
module into opening in fuel tank.
(3) Position locknut over top of fuel tank module.
Install locknut finger tight.
(4) When looking down at tank from drivers side of
tank, the fuel line connectors and fuel gauge electri-
cal connector should all be pointed to drivers side of
vehicle. Rotate and align if necessary before tighten-
ing locknut.This step must be performed to pre-
vent the module's float from contacting side of
fuel tank.
(5) Tighten locknut to 24 - 44 N´m (18 - 32 ft. lbs.)
torque.
(6) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
FUEL TRANSFER PUMP
DESCRIPTION
The fuel transfer pump (fuel lift pump) is attached
to the rear of the fuel filter/water separator housing.
The 12±volt electric pump is operated and controlled
by the Engine Control Module (ECM).
OPERATION
The purpose of the fuel transfer pump is to supply
(transfer) a low-pressure fuel source:fromthe fuel
tank,throughthe fuel filter/water separator andto
the fuel injection pump. Here, the low-pressure is
raised to a high-pressure by the fuel injection pump
for operation of the high-pressure fuel injectors.
Check valves within the pump, control direction of
fuel flow and prevent fuel bleed-back during engine
shut down.
Maximum current flow to the pump is 5 amperes.
With the engine running, the pump has a 100 per-
cent duty-cycle.
The transfer pump is self-priming: When the key is
first turned on (without cranking engine), the pump
will operate for approximately 2 seconds and then
shut off. The pump will also operate for up to 25 sec-
onds after the starter is engaged, and then disen-
gaged and the engine is not running. The pump
shuts off immediately if the key is on and the engine
stops running.
The fuel volume of the transfer pump will always
provide more fuel than the fuel injection pump
requires. Excess fuel is returned from the injection
pump through an overflow valve, and then back to
the fuel tank.
REMOVAL
The fuel transfer pump (fuel lift pump) is attached
to the rear of the fuel filter/water separator housing
(Fig. 23).
Fig. 21 FUEL TANK MODULE - DIESEL
1 - TOP OF FUEL TANK
2 - AUX. FITTING
3 - ELEC. CONNECTOR
4 - FUEL TANK MODULE (TOP)
5 - LOCKNUT
6 - FUEL SUPPLY LINE
7 - FUEL RETURN LINE
Fig. 22 LOCKNUT REMOVAL/INSTALLATION -
TYPICAL MODULE
1 - SPECIAL TOOL 6856
2 - LOCKNUT
14 - 64 FUEL DELIVERY - DIESELDR
FUEL TANK MODULE (Continued)