One DODGE RAM 1500 1998 2.G Workshop Manual

(25) Confirm alignment of the replacement frame
rail tip. (Fig. 14)
(26) Final welding should be performed in a skip
(stitch) type method to minimize the heat buildup
and frame distortion, utilizing the Weld Process
Specifications at the end of this section. The pre-
ferred method is GMAW (MIG). (Refer to 13 -
FRAME & BUMPERS/FRAME - SPECIFICATIONS -
WELDING)
(a) Apply root pass welds to the root joint one
quadrant at a time, switching to the opposite side
of the frame for each quadrant. (Fig. 8)
(b) Clean the welds of any flux and other impu-
rities before proceeding with the cover pass welds.
(c) Apply the cover pass welds in the same man-
ner as described above.
(27) Confirm alignment of the replacement frame
rail tip. (Fig. 14)
NOTE: Any burned surface coatings will need to be
removed prior to application of corrosion preventa-
tive coatings.
(28) Dress the welded area and apply corrosion
resistant coatings inside and out.
(a) Apply etch-primer to the inside of the frame
rail repair area.
(b) Inside the rail, inject a creeping wax based
rust inhibitor compound through the existing holes
in the frame ensuring 100% coverage including the
space between the original frame rail and the rein-
forcing sleeve.
(c) Apply a durable top coat to the outside of the
repair area.
(29) Tighten the front cab mounting bolt to the
FESM bracket to 81 N´m (60 ft. lbs.).(30) Install the stabilizer bar. (Refer to 2 - SUS-
PENSION/FRONT/STABILIZER BAR - INSTALLA-
TION)
(31) Install the front bumper. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT BUMPER
- INSTALLATION)
(32) Install the wire harness and ground strap if
previously removed and install the bolt.
(a) If necessary, re-drill and tap the ground
strap mounting hole
(33) Install the front wheelhouse splash shield.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION)
Fig. 13 RING FILLET WELD
1 - WELD START LOCATION
2 - WELD END LOCATION
3 - RING-FILLET WELD
Fig. 14 FRAME TIP DIMENSIONS
1 - PLP POINT
2 - FRAME
3 - PLP POINT
4 - REPLACEMENT FRAME TIP
DRFRAMES & BUMPERS 13 - 9
FRAME (Continued)

(14) Remove the bolts attaching the lower radiator
crossmember to the hydroform fender rail. (Fig. 18)
CAUTION: Do not use any flame or plasma cutting
equipment to cut the frame in this procedure. The
inaccurate and high temperatures achieved during
flame or plasma cutting will change the metal char-
acteristics and may weaken the frame and/or repair
location.
(15) Using a reciprocating saw or equivalent, cut
the fender rail and shotgun at a straight and square
section of the hydroform and remove.
(16) Smooth and square the cut edges.
(17) Using the damaged structure as a reference
cut the service part at the same location as the first
cut. Smooth and square the cut edges.
NOTE: The repair structure should butt up to the
remaining structure and provide the same overall
vehicle geometry.
(18) Fabricate 51 mm (2.0 in.) long repair inserts
using scrap from the old structure or the replacement
part. It will be necessary to split the inserts on each
of their four sides to fit into the hydroform.
(19) Remove any paint or e-coat from the inserts
and also to the interior and exterior of the hydro-
forms.
(20) Cut plug weld holes as described below.
²On the upper rail, cut one 13 mm (0.5 in.) hole
on each side of the rail, 25 mm (1.0 in.) from the butt
joint of the tubes.
²On the lower rail, cut one 13 mm (0.5 in.) hole
on the top and bottom sides of the rail 25 mm (1.0
in.) from the butt joint of the tube.
²On the lower rail, cut two 13 mm (0.5 in.) holes
on the inner and outer sides of the rail 25 mm (1.0
in.) from the butt joint of the tube.
CAUTION: Shield the surrounding area and compo-
nents from exposure to the welding spatter and
heat.
(21) Install the insert 1º into the replacement part
and tack into place with a weld. (Refer to 13 -
FRAME & BUMPERS/FRAME - SPECIFICATIONS -
WELDING)
(22) Insert the service part into place and using
the appropriate measuring equipment, verify the
front end sheet metal bracket's location in all three
(X,Y, and Z) planes of space. (Fig. 19)
(23) Complete all 360É plug welds.
NOTE: Before the final welding, use three dimen-
sional measuring equipment to ensure the part is in
the correct location. Verify that tap plate extrusion
at the bottom of the vertical post lines up with theisolator and hole in the frame perch mount. Also
ensure the lower radiator closure tube is bolted into
the forward shotgun ends.
(24) Complete welding by making a 360É butt weld
around the fender rails.
(25) Metal finish the exposed welds on the hydro-
forms.
(26) Dress the welded area and apply corrosion
resistant coatings inside and out.
(a) Inside the rail, inject a creeping wax based
rust inhibitor compound to the inside of the hydro-
forms ensuring 100% coverage including the mat-
ing face between the fender rail sections and insert
such that corrosion protection is restored in the
internal cavity.
(b) Apply a durable top coat to the outside of the
repair area.
(27) Install the front cab mount bolt if previously
removed and tighten to 81 N´m (60 ft. lbs.).
(28) Install the lower radiator crossmember bolts
and tighten to 28 N´m (21 ft. lbs.).
(29) Install the headlamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - INSTALLATION)
(30) Install the upper radiator crossmember. (Refer
to 23 - BODY/EXTERIOR/UPPER RADIATOR
CROSSMEMBER - INSTALLATION)
(31) Install the wire harness and ground if previ-
ously removed and install the bolts.
(32) Install the integrated power module, if previ-
ously removed. (Refer to 8 - ELECTRICAL/POWER
DISTRIBUTION/INTEGRATED POWER MODULE -
INSTALLATION)
(33) Install the air cleaner bracket and air cleaner,
if previously removed. (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER ELEMENT -
INSTALLATION)
(34) Install the radiator assembly. (Refer to 7 -
COOLING/ENGINE/RADIATOR - INSTALLATION)
(35) Install the A/C lines, if previously removed.
Refer to the Heating and Air Conditioning section of
the manual for the recommended procedures.
(36) Install the A/C condenser, if previously
removed. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C CONDENSER - INSTAL-
LATION)
(37) Install the fender. (Refer to 23 - BODY/EXTE-
RIOR/FRONT FENDER - INSTALLATION)
(38) Install the front wheelhouse splash shield.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION)
(39) Reconnect the battery ground.
13 - 12 FRAMES & BUMPERSDR
FRAME (Continued)

(9) Remove the clip and remove the spare tire
winch tube. (Fig. 21)
(10) Remove the bolts and remove the spare tire
winch. (Fig. 22)
(11) Position the wire harness forward of the work
area.
CAUTION: Do not use any flame or plasma cutting
equipment to cut the frame in this procedure. The
inaccurate and high temperatures achieved during
flame or plasma cutting will change the metal char-
acteristics and may weaken the frame and/or repair
location.(12) Carefully remove the H-section welds using a
grinder or equivalent tool.
(13) Remove the H-section and clean any remain-
ing welds from the frame.
(14) Trial fit the replacement part.
(15) Remove all e-coat from within 25 mm (1.0 in.)
of the weld area.
(16) Using the appropriate measuring equipment,
position the replacement part and verify correct posi-
tioning in all three (X,Y, and Z) planes of space.
(Refer to 13 - FRAME & BUMPERS/FRAME - SPEC-
IFICATIONS - FRAME DIMENSIONS)
CAUTION: Shield the surrounding area and compo-
nents from exposure to the welding spatter and
heat.
(17) Weld the replacement H-section into position.
The welding should be performed in a skip (stitch)
type method to minimize the heat buildup following
I-CAR or the American Welding Society welding pro-
cedures and utilizing the process specifications at the
end of this section. (Refer to 13 - FRAME &
BUMPERS/FRAME - SPECIFICATIONS - WELD-
ING)
(18) Dress the welded area and apply corrosion
resistant coatings inside and out.
(a) Inside the rail, inject a creeping wax based
rust inhibitor compound through the existing holes
in the frame ensuring 100% coverage including the
mating face between the frame and replacement
H-section.
(b) Apply a durable top coat to the outside of the
repair area.
(19) Position the wiring harness back.
CAUTION: Inspect the tire winch assembly for dam-
age. If any one or more of the following are evident,
replace the winch assembly.
²Indications of cracked or bulging plastic.
²Housing flanges are bent or cracked.
²If winch was loose before repair.
(20) Install the spare tire winch and install the
bolts. (Fig. 22)
(21) Tighten the bolts to 41 N´m (30 ft. lbs.).
(22) Install the spare tire winch tube and install
the clip. (Fig. 21)
(23) Install the spare tire.
CAUTION: Check operation of the spare tire winch
by manipulating it up and down. If the winch binds
or jambs, replace the winch assembly.
(24) Lift the axle into position and install the rear
shackle bolts. (Fig. 20)
(25) Tighten the bolts to 163 N´m (120 ft. lbs.).
Fig. 21 SPARE TIRE WINCH TUBE
1 - SPARE TIRE WINCH ASSEMBLY
2 - HAIR PIN CLIP
3 - WINCH TUBE
4 - H-SECTION/SPARE WHEEL SUPPORT
Fig. 22 SPARE TIRE WINCH ASSEMBLY
1 - SPARE TIRE WINCH ASSEMBLY
2 - BOLTS
3 - RETAINER BRACKET
4 - H-SECTION/SPARE WHEEL SUPPORT
13 - 14 FRAMES & BUMPERSDR
FRAME (Continued)

FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY - GAS....................1
FUEL INJECTION - GAS...................21FUEL DELIVERY - DIESEL.................44
FUEL INJECTION - DIESEL................68
FUEL DELIVERY - GAS
TABLE OF CONTENTS
page page
FUEL DELIVERY - GAS
DESCRIPTION..........................1
OPERATION............................2
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE...................2
SPECIFICATIONS
FUEL SYSTEM PRESSURE..............3
TORQUE - FUEL SYSTEM - EXCEPT
DIESEL..............................3
SPECIAL TOOLS
FUEL SYSTEM........................5
FUEL FILTER/PRESSURE REGULATOR
DESCRIPTION..........................5
OPERATION............................6
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION..........................6
OPERATION............................6
REMOVAL.............................7
INSTALLATION..........................7
FUEL LINES
DESCRIPTION..........................7
QUICK CONNECT FITTING
DESCRIPTION..........................8STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS............................8
FUEL PUMP
DESCRIPTION.........................11
OPERATION...........................11
FUEL PUMP MODULE
DESCRIPTION.........................11
OPERATION...........................11
REMOVAL.............................12
INSTALLATION.........................12
FUEL RAIL
DESCRIPTION.........................12
OPERATION...........................12
REMOVAL.............................13
INSTALLATION.........................15
FUEL TANK
DESCRIPTION.........................17
OPERATION...........................17
REMOVAL- EXCEPT DIESEL..............17
INSTALLATION - EXCEPT DIESEL..........19
INLET FILTER
REMOVAL.............................20
INSTALLATION.........................20
FUEL DELIVERY - GAS
DESCRIPTION
The fuel delivery system consists of:
²a fuel pump module containing the electric fuel
pump, fuel filter/fuel pressure regulator, fuel gauge
sending unit (fuel level sensor) and a secondary fuel
filter located at the bottom of the pump module
²fuel tubes/lines/hoses
²a combination fuel filter/fuel pressure regulator
²quick-connect fittings²fuel injector rail
²fuel tank
²fuel tank filler/vent tube assembly
²fuel tank filler tube cap
²accelerator pedal
²throttle cable
Certain fuel delivery components can be found in
(Fig. 1).
DRFUEL SYSTEM 14 - 1

OPERATION
Fuel is returned through the fuel pump module
and back into the fuel tank through the fuel filter/
fuel pressure regulator. A separate fuel return line
from the engine to the tank is not used.
The fuel tank assembly consists of: the fuel tank,
fuel pump module assembly, fuel pump module lock-
nut/gasket, and fuel tank check valve (refer to Fuel
Tank Check Valve for information).
A fuel filler/vent tube assembly using a pressure/
vacuum, 1/4 turn fuel filler cap is used. The fuel
filler tube contains a flap door located below the fuel
fill cap.
Also to be considered part of the fuel system is the
evaporation control system. This is designed to
reduce the emission of fuel vapors into the atmo-sphere. The description and function of the Evapora-
tive Control System is found in Emission Control
Systems.
Both fuel filters (at bottom of fuel pump module
and within fuel pressure regulator) are designed for
extended service. They do not require normal sched-
uled maintenance. Filters should only be replaced if
a diagnostic procedure indicates to do so.
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fill cap.
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
14 - 2 FUEL DELIVERY - GASDR
FUEL DELIVERY - GAS (Continued)

(2) Remove fuel pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(3) Start and run engine until it stalls.
(4) Attempt restarting engine until it will no
longer run.
(5) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unplug connector from any fuel injector.
(7) Attach one end of a jumper wire with alligator
clips (18 gauge or smaller) to either injector terminal.
(8) Connect other end of jumper wire to positive
side of battery.(9) Connect one end of a second jumper wire to
remaining injector terminal.
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentarily touch other end of jumper wire
to negative terminal of battery for no more than a
few seconds.
(11) Place a rag or towel below fuel line quick-con-
nect fitting at fuel rail.
(12) Disconnect quick-connect fitting at fuel rail.
Refer to Quick-Connect Fittings.
(13) Return fuel pump relay to PDC.
(14) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRBtscan tool must be
used to erase a DTC.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
58 psi +/- 2 psi
TORQUE - FUEL SYSTEM - EXCEPT DIESEL
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Accelerator Pedal Bracket
Mounting12 - 105
Accelerator Pedal Position
Sensor Bracket-to-Battery
Tray Bolts3-30
Crankshaft Position
Sensor - 3.7L28 21 -
Crankshaft Position
Sensor - 4.7L28 21 -
Crankshaft Position
Sensor - 5.7L12 - 105 (+/-20)
Camshaft Position Sensor
- 3.7L12 - 106
Camshaft Position Sensor
- 4.7L12 - 106
Camshaft Position Sensor
- 5.7L12 9 105 (+/-) 20
Engine Coolant
Temperature Sensor -
3.7L11 - 9 6
Engine Coolant
Temperature Sensor -
4.7L11 - 9 6
DRFUEL DELIVERY - GAS 14 - 3
FUEL DELIVERY - GAS (Continued)

QUICK CONNECT FITTING
DESCRIPTION
Different types of quick-connect fittings are used to
attach various fuel system components, lines and
tubes. These are: a single-tab type, a two-tab type or
a plastic retainer ring type. Some are equipped with
safety latch clips. Some may require the use of a spe-
cial tool for disconnection and removal. Refer to
Quick-Connect Fittings Removal/Installation for more
information.
CAUTION: The interior components (o-rings, clips)
of quick-connect fittings are not serviced sepa-
rately, but new plastic spacers are available for
some types. If service parts are not available, do
not attempt to repair the damaged fitting or fuel line
(tube). If repair is necessary, replace the complete
fuel line (tube) assembly.
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS
Also refer to Fuel Tubes/Lines/Hoses and Clamps.
Different types of quick-connect fittings are used to
attach various fuel system components, lines and
tubes. These are: a single-tab type, a two-tab type or
a plastic retainer ring type. Safety latch clips are
used on certain components/lines. Certain fittings
may require use of a special tool for disconnection.
DISCONNECTING
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSE,
FITTING OR LINE, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
CAUTION: The interior components (o-rings, spac-
ers) of some types of quick-connect fitting are not
serviced separately. If service parts are not avail-
able, do not attempt to repair a damaged fitting or
fuel line. If repair is necessary, replace complete
fuel line assembly.
(1) Perform fuel pressure release procedure. Refer
to Fuel Pressure Release Procedure.
(2) Disconnect negative battery cable from battery.
(3) Clean fitting of any foreign material before dis-
assembly.
(4)2±Button Type Fitting:This type of fitting is
equipped with a push-button located on each side of
quick-connect fitting (Fig. 5). Press on both buttonssimultaneously for removal. Special tools are not
required for disconnection.
(5)Pinch-Type Fitting:This fitting is equipped
with two finger tabs. Pinch both tabs together while
removing fitting (Fig. 6). Special tools are not
required for disconnection.
Fig. 5 2-BUTTON TYPE FITTING
1 - QUICK-CONNECT FITTING
2 - PUSH-BUTTONS (2)
Fig. 6 PINCH TYPE QUICK-CONNECT FITTING
1 - QUICK-CONNECT FITTINGS
2 - PINCH TABS
14 - 8 FUEL DELIVERY - GASDR

(6)Single-Tab Type Fitting:This type of fitting
is equipped with a single pull tab (Fig. 7). The tab is
removable. After tab is removed, quick-connect fitting
can be separated from fuel system component. Spe-
cial tools are not required for disconnection.
(a) Press release tab on side of fitting to release
pull tab (Fig. 8).If release tab is not pressed
prior to releasing pull tab, pull tab will be
damaged.
(b) While pressing release tab on side of fitting,
use screwdriver to pry up pull tab (Fig. 8).
(c) Raise pull tab until it separates from quick-
connect fitting (Fig. 9).
(7)Two-Tab Type Fitting:This type of fitting is
equipped with tabs located on both sides of fitting
(Fig. 10). The tabs are supplied for disconnecting
quick-connect fitting from component being serviced.
(a) To disconnect quick-connect fitting, squeeze
plastic retainer tabs (Fig. 10) against sides of
quick-connect fitting with your fingers. Tool use is
not required for removal and may damage plastic
retainer.
(b) Pull fitting from fuel system component
being serviced.
(c) The plastic retainer will remain on compo-
nent being serviced after fitting is disconnected.
The o-rings and spacer will remain in quick-con-
nect fitting connector body.
(8)Plastic Retainer Ring Type Fitting:This
type of fitting can be identified by the use of a full-
round plastic retainer ring (Fig. 11) usually black in
color.(a) To release fuel system component from quick-
connect fitting, firmly push fitting towards compo-
nent being serviced while firmly pushing plastic
retainer ring into fitting (Fig. 11). With plastic ring
depressed, pull fitting from component.The plas-
tic retainer ring must be pressed squarely
into fitting body. If this retainer is cocked
during removal, it may be difficult to discon-
nect fitting. Use an open-end wrench on
shoulder of plastic retainer ring to aid in dis-
connection.
(b) After disconnection, plastic retainer ring will
remain with quick-connect fitting connector body.
Fig. 7 SINGLE-TAB TYPE FITTING
1 - PULL TAB
2 - QUICK-CONNECT FITTING
3 - PRESS HERE TO REMOVE PULL TAB
4 - INSERTED TUBE END
Fig. 8 DISCONNECTING SINGLE-TAB TYPE FITTING
1 - PULL TAB
2 - SCREWDRIVER
3 - QUICK-CONNECT FITTING
Fig. 9 REMOVING PULL TAB
1 - FUEL TUBE OR FUEL SYSTEM COMPONENT
2 - PULL TAB
3 - QUICK-CONNECT FITTING
4 - FUEL TUBE STOP
DRFUEL DELIVERY - GAS 14 - 9
QUICK CONNECT FITTING (Continued)

(c) Inspect fitting connector body, plastic retainer
ring and fuel system component for damage.
Replace as necessary.
(9)Latch Clips:Depending on vehicle model and
engine, 2 different types of safety latch clips are used
(Fig. 12) or (Fig. 13). Type-1 is tethered to fuel line
and type-2 is not. A special tool will be necessary todisconnect fuel line after latch clip is removed. The
latch clip may be used on certain fuel line/fuel rail
connection, or to join fuel lines together.
(a) Type 1: Pry up on latch clip with a screw-
driver (Fig. 12).
(b) Type 2: Separate and unlatch 2 small arms
on end of clip (Fig. 13) and swing away from fuel
line.
(c) Slide latch clip toward fuel rail while lifting
with screwdriver.
Fig. 10 TYPICAL 2±TAB TYPE FITTING
1 - TAB(S)
2 - QUICK-CONNECT FITTING
Fig. 11 PLASTIC RETAINER RING TYPE FITTING
1 - FUEL TUBE
2 - QUICK CONNECT FITTING
3 - PUSH
4 - PLASTIC RETAINER
5 - PUSH
6 - PUSH
7 - PUSH
8 - PUSH
Fig. 12 LATCH CLIP-TYPE 1
1 - TETHER STRAP
2 - FUEL LINE
3 - SCREWDRIVER
4 - LATCH CLIP
5 - FUEL RAIL
Fig. 13 LATCH CLIP-TYPE 2
1 - LATCH CLIP
14 - 10 FUEL DELIVERY - GASDR
QUICK CONNECT FITTING (Continued)

(d) Insert special fuel line removal tool (Snap-On
number FIH 9055-1 or equivalent) into fuel line
(Fig. 14). Use tool to release locking fingers in end
of line.
(e) With special tool still inserted, pull fuel line
from fuel rail.
(f) After disconnection, locking fingers will
remain within quick-connect fitting at end of fuel
line.
(10) Disconnect quick-connect fitting from fuel sys-
tem component being serviced.
CONNECTING
(1) Inspect quick-connect fitting body and fuel sys-
tem component for damage. Replace as necessary.
(2) Prior to connecting quick-connect fitting to
component being serviced, check condition of fitting
and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.
(3) Insert quick-connect fitting into fuel tube or
fuel system component until built-on stop on fuel
tube or component rests against back of fitting.
(4) Continue pushing until a click is felt.
(5) Single-tab type fitting: Push new tab down
until it locks into place in quick-connect fitting.
(6) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.).
(7) Latch Clip Equipped: Install latch clip (snaps
into position).If latch clip will not fit, this indi-
cates fuel line is not properly installed to fuel
rail (or other fuel line). Recheck fuel line con-
nection.
(8) Connect negative cable to battery.
(9) Start engine and check for leaks.
FUEL PUMP
DESCRIPTION
The electric fuel pump is located inside of the fuel
pump module. A 12 volt, permanent magnet, electric
motor powers the fuel pump. The electric fuel pump
is not a separate, serviceable component.
OPERATION
Voltage to operate the electric pump is supplied
through the fuel pump relay.
Fuel is drawn in through a filter at the bottom of
the module and pushed through the electric motor
gearset to the pump outlet.
Check Valve Operation:The bottom section of
the fuel pump module contains a one-way check
valve to prevent fuel flow back into the tank and to
maintain fuel supply line pressure (engine warm)
when pump is not operational. It is also used to keep
the fuel supply line full of gasoline when pump is not
operational. After the vehicle has cooled down, fuel
pressure may drop to 0 psi (cold fluid contracts), but
liquid gasoline will remain in fuel supply line
between the check valve and fuel injectors.Fuel
pressure that has dropped to 0 psi on a cooled
down vehicle (engine off) is a normal condition.
The electric fuel pump is not a separate, service-
able component.
FUEL PUMP MODULE
DESCRIPTION
The fuel pump module assembly is located on the
top of the fuel tank (Fig. 1). The complete assembly
contains the following components:
²A combination fuel filter/fuel pressure regulator
²A separate fuel pick-up, or inlet filter
²An electric fuel pump
²A lockring to retain pump module to tank
²A soft gasket between tank flange and module
²A fuel gauge sending unit (fuel level sensor)
²Fuel line connection
The fuel gauge sending unit may be serviced sepa-
rately. If the electrical fuel pump, primary inlet filter,
fuel filter or fuel pressure regulator require service,
the fuel pump module must be replaced.
OPERATION
Refer to Fuel Pump, Inlet Filter, Fuel Filter / Fuel
Pressure Regulator and Fuel Gauge Sending Unit.
Fig. 14 FUEL LINE DISCONNECTION USING
SPECIAL TOOL
1 - SPECIAL FUEL LINE TOOL
2 - FUEL LINE
3 - FUEL RAIL
DRFUEL DELIVERY - GAS 14 - 11
QUICK CONNECT FITTING (Continued)