tow DODGE RAM 2001 Service Repair Manual

DIMENSIONS FOR DIFFERING WHEELBASES*
WHEELBASE LENGTH
ALENGTH
BLENGTH
C
118 2118.0 3663.6 4185.4
134 2118.0 3994.5 4693.4
138 2626.0 4096.1 4693.4
154 2626.0 4502.5 5201.4
162 2118.0 4705.0 5042.5
*Measurements are in Millimeters (mm).
TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Cab Chassis adapter nut..... 108N´m(80ft.lbs.)
Front bumper brkt-to-frame nut . 68 N´m (50 ft. lbs.)
Front bumper outer brace bolt . . 68 N´m (50 ft. lbs.)
Rear bumper-to-brace nut..... 40N´m(30ft.lbs.)
Rear bumper brace-to-brkt nut . 101 N´m (75 ft. lbs.)
Rear bumper brkt-to-frame nut......... 101N´m
(75 ft. lbs.)
Skid plate crossmember-to-frame bolt..... 54N´m
(40 ft. lbs.)
Skid plate-to-crossmember bolt . 40 N´m (30 ft. lbs.)
Skid plate-to-trans crossmember bolt...... 54N´m
(40 ft. lbs.)
Spare tire winch bolt......... 27N´m(20ft.lbs.)
Trailer hitch nut............ 108N´m(80ft.lbs.)
CAB CHASSIS ADAPTER
BRACKET
REMOVAL
(1) Remove bolts attaching cab chassis adapter
brackets to frame rail (Fig. 11)
(2) Separate cab chassis adapter brackets from
frame rail
INSTALLATION
(1) Position cab chassis adapter brackets on frame
rail
(2) Install bolts attaching cab chassis adapter
brackets to frame rail.
FRONT TOW HOOK
REMOVAL
Some vehicles are equipped with front tow hooks.
The tow hooks are to be used forEMERGENCYpur-
poses only.(1) Remove the fasteners that attach the tow
hooks to the frame (Fig. 12).
(2) Separate the tow hooks from the frame.
Fig. 11 Cab Chassis Adapter Brackets
1 - ADAPTER BRACKETS
2 - FRAME
Fig. 12 Front Tow Hooks
1 - TOW HOOK
2 - FRAME
BR/BEFRAME & BUMPERS 13 - 9
SPECIFICATIONS (Continued)

Installation
Some vehicles are equipped with front tow hooks.
The tow hooks are to be used forEMERGENCYpur-
poses only.
(1) Position the tow hooks on the frame.
(2) Install the fasteners that attach the tow hooks
to the frame.
(3) Tighten the nuts to 108 N´m (80 ft. lbs.) torque.
SPARE TIRE WINCH
REMOVAL
(1) Remove spare tire from under vehicle.
(2) Remove cotter pin attaching winch tube to
spare tire winch.
(3) Pull winch tube from spare tire winch.
(4) Remove bolts attaching spare tire winch to
crossmember (Fig. 13).
(5) Separate spare tire winch from vehicle.
INSTALLATION
(1) Position spare tire winch on vehicle.
(2) Install bolts holding spare tire winch to spare
crossmember.
(3) Insert winch tube into spare tire winch.
(4) Install cotter pin attaching winch tube to spare
tire winch.
(5) Install spare tire.
TRAILER HITCH
REMOVAL
(1) Support trailer hitch on a suitable lifting
device.(2) Remove fasteners attaching trailer wiring con-
nector to trailer hitch, if equipped.
(3) Remove bolts attaching trailer hitch to frame
rails (Fig. 14).
(4) Separate trailer hitch from vehicle.
INSTALLATION
(1) Position trailer hitch on vehicle.
(2) Install nuts attaching trailer hitch to frame
rails. Tighten nuts to 108 N´m (80 ft. lbs.) torque.
(3) Install fasteners attaching trailer wiring con-
nector to trailer hitch, if equipped.
Fig. 13 Spare Tire Winch
1 - CROSSMEMBER
2 - GROMMET
3 - WINCH TUBE
4 - SPARE TIRE WINCH
5 - COTTER PIN
13 - 10 FRAME & BUMPERSBR/BE
FRONT TOW HOOK (Continued)

(4) Connect the 0-414 kPa (0-60 psi) fuel pressure
test gauge (from Gauge Set 5069) to the test port on
the appropriate Adaptor Tool.The DRBtIII Scan
Tool along with the PEP module, the 500 psi
pressure transducer, and the transducer-to-test
port adapter may also be used in place of the
fuel pressure gauge.
The fittings on both tools must be in good
condition and free from any small leaks before
performing the proceeding test.
(5) Start engine and bring to normal operating
temperature.
(6) Observe test gauge. Normal operating pressure
should be 339 kPa +/±34 kPa (49.2 psi +/±5 psi).
(7) Shut engine off.
(8) Pressure should not fall below30 psi for five
minutes.
(9) If pressure falls below 30 psi, it must be deter-
mined if a fuel injector, the check valve within the
fuel pump module, or a fuel tube/line is leaking.
(10) Again, start engine and bring to normal oper-
ating temperature.
(11) Shut engine off.
(12)Testing for fuel injector or fuel rail leak-
age:Clamp off the rubber hose portion of Adaptor
Tool between the fuel rail and the test port ªTº on
Adapter Tool. If pressure now holds at or above 30
psi, a fuel injector or the fuel rail is leaking.
(13)Testing for fuel pump check valve, filter/
regulator check valve or fuel tube/line leakage:
Clamp off the rubber hose portion of Adaptor Tool
between the vehicle fuel line and test port ªTº on
Adapter Tool. If pressure now holds at or above 30
psi, a leak may be found at a fuel tube/line. If no
leaks are found at fuel tubes or lines, one of the
check valves in either the electric fuel pump or filter/
regulator may be leaking.
Note: A quick loss of pressure usually indicates a
defective check valve in the filter/regulator. A slow
loss of pressure usually indicates a defective check
valve in the electric fuel pump.
The electric fuel pump is not serviced separately.
Replace the fuel pump module assembly. The filter/
regulator may be replaced separately on certain
applications. Refer to Fuel Filter/Fuel Pressure Reg-
ulator Removal/Installation for additional informa-
tion.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.
(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.
BR/BEFUEL DELIVERY - GASOLINE 14 - 3
FUEL DELIVERY - GASOLINE (Continued)

(4) Press filter/regulator (by hand) into rubber
grommet. The assembly should be pointed towards
drivers side of vehicle (Fig. 4) or (Fig. 5).
(5) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
(6) Check for fuel leaks.
FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge sending unit (fuel level sensor) is
attached to the side of the fuel pump module. The
sending unit consists of a float, an arm, and a vari-
able resistor track (card).
OPERATION
The fuel pump module has 4 different circuits
(wires). Two of these circuits are used for the fuel
gauge sending unit for fuel gauge operation, and for
certain OBD II emission requirements. The other 2
wires are used for electric fuel pump operation.
For Fuel Gauge Operation:A constant current
source of about 32 mA is supplied to the resistor
track on the fuel gauge sending unit. This is fed
directly from the Powertrain Control Module (PCM).
The resistor track is used to vary the voltage depend-
ing on fuel tank float level. As fuel level increases,
the float and arm move up, which decreases voltage.
As fuel level decreases, the float and arm move
down, which increases voltage. The varied voltage
signal is returned back to the PCM through the sen-
sor return circuit. Output voltages will vary from
about .6 volts at FULL, to about 8.6 volts at EMPTY
(Jeep models), or, about 7.0 volts at EMPTY (Dodge
Truck models).NOTE: For diagnostic purposes,
this voltage can only be verified with the fuel
gauge sending unit circuit closed (i.e. having all
of the sending units electrical connectors con-
nected).
Fig. 6 Filter/Regulator Removal and InstallationÐ
TYPICAL
1 - RUBBER GROMMET
2 - FUEL FILTER/FUEL PRESSURE REGULATOR
Fig. 7 Fuel Tube and ClampÐTYPICAL
1 - FUEL FILTER/FUEL PRESSURE REGULATOR
2 - TUBE CLAMP
3 - FUEL TUBE
Fig. 8 Tightening Fuel Tube ClampÐTYPICAL
1 - TOOL C-4124
2 - TUBE CLAMP
3 - FUEL TUBE
BR/BEFUEL DELIVERY - GASOLINE 14 - 7
FUEL FILTER/PRESSURE REGULATOR (Continued)

(6)Open fuel fill door and remove screws mounting
fuel filler tube assembly to body. Do not disconnect
rubber fuel fill or vent hoses from tank at this time.
(7) Place a transmission jack under center of fuel
tank. Apply a slight amount of pressure to fuel tank
with transmission jack.
(8) Remove fuel tank mounting strap nuts from
mounting strap studs (Fig. 35). If equipped, remove
fuel tank shield bolts.
(9) Lower fuel tank only enough to allow access to
top of tank. The 2 tank fittings (where rubber fuel fill
and vent hose connections are made) must be posi-
tioned above tank level. Rotate tank slightly to allow
these fittings to be above tank level.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(10) While working over left rear tire/wheel, dis-
connect rubber fuel vent hose at fuel tank (Fig. 35)
(vent hose is the smallest of 2 hoses). Position fuel
siphoning/drain hose into this fitting at tank. Drain
fuel into an approved portable holding tank or a
properly labeled gasoline (or diesel fuel) safety con-
tainer.
(11) Disconnect rubber fuel fill hose at fuel tank
(Fig. 35).
(12)Gas Powered Engines:
(a) While working over left rear tire/wheel, dis-
connect wiring harness connector from electrical
connector at top of fuel pump module (Fig. 36) or
(Fig. 37).
(b) If equipped with 26 or 34 gallon fuel tank,
two EVAP lines are connected to rollover valves.
Disconnect EVAP line from rollover valve at top of
module (Fig. 36). Disconnect other EVAP line from
rollover valve near rear of tank (Fig. 36).
(c) If equipped with 35 gallon fuel tank, two
EVAP lines are connected to rollover valves. Dis-
connect EVAP lines from rollover valves at top-
front and top-rear of fuel tank (Fig. 38).
(d) Disconnect fuel supply line at fuel filter/fuel
pressure regulator supply fitting (Fig. 36) or (Fig.
37). Refer to Quick-Connect Fittings for proce-
dures.
(13)Diesel Powered Engines:
(a) While working over left rear tire/wheel, dis-
connect wiring harness connector from electrical
connector at top of fuel tank module (Fig. 39).
(b) Disconnect fuel supply and fuel return lines
at the fuel tank module fittings (Fig. 39). Refer to
Quick-Connect Fittings for procedures.
(14) Gasoline Engines: If fuel pump module
removal is necessary, refer to Fuel Pump Module
Removal/Installation in this group. Diesel Engines: If
fuel tank module removal is necessary, refer to Fuel
Tank Module Removal/Installation in this group.
INSTALLATION
(1) Gasoline Engines: If fuel pump module is being
installed, refer to Fuel Pump Module Removal/Instal-
lation in this group. Diesel Engines: If fuel tank mod-
ule is being installed, refer to Fuel Tank Module
Removal/Installation in this group.
(2) Place fuel tank on top of transmission jack.
(3) Install rubber fill and vent lines to tank.
Tighten hose clamps to 2.3 N´m (20 in. lbs.) torque.
(4) Raise tank into position while guiding fill and
vent hoses to body. Raise tank only enough to allow
access to top of tank.
(5)Gas Powered Engines:
(a) Connect electrical connector to fuel pump
module.
(b) Connect EVAP hoses at rollover valves.
(c) Connect fuel supply line at fuel filter/fuel
pressure regulator. Refer to Quick-Connect Fittings
for procedures.
(6)Diesel Powered Engines:
(a) Connect electrical connector to fuel tank
module.
Fig. 35 Fuel Tank MountingÐTypical
1 - STRAP MOUNTING STUDS (AT FRAME)
2 - FUEL FILL HOSE
3 - FUEL VENT HOSE
4 - STRAP MOUNTING NUTS (2)
5 - FUEL TANK STRAPS (2)
6 - FUEL TANK
7 - CLAMPS
14 - 20 FUEL DELIVERY - GASOLINEBR/BE
FUEL TANK (Continued)

(3) Clean fitting of any foreign material before dis-
assembly.
(4)Single-Tab Type Fitting:This type of fitting
is equipped with a single pull tab (Fig. 41). The tab
is removable. After tab is removed, quick-connect fit-
ting can be separated from fuel system component.
(a) Press release tab on side of fitting to release
pull tab (Fig. 42).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. 42).
(c) Raise pull tab until it separates from quick-
connect fitting (Fig. 43).
(5)Two-Tab Type Fitting:This type of fitting is
equipped with tabs located on both sides of fitting
(Fig. 44). The tabs are supplied for disconnecting
quick-connect fitting from component being serviced.
(a) To disconnect quick-connect fitting, squeeze
plastic retainer tabs (Fig. 44) 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.
(6)Plastic Retainer Ring Type Fitting:This
type of fitting can be identified by the use of a full-
round plastic retainer ring (Fig. 45) 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. 45). 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. 41 Single-Tab Type Fitting
1 - PULL TAB
2 - QUICK-CONNECT FITTING
3 - PRESS HERE TO REMOVE PULL TAB
4 - INSERTED TUBE END
Fig. 42 Disconnecting Single-Tab Type Fitting
1 - PULL TAB
2 - SCREWDRIVER
3 - QUICK-CONNECT FITTING
Fig. 43 Removing Pull Tab
1 - FUEL TUBE OR FUEL SYSTEM COMPONENT
2 - PULL TAB
3 - QUICK-CONNECT FITTING
4 - FUEL TUBE STOP
BR/BEFUEL DELIVERY - GASOLINE 14 - 23
QUICK CONNECT FITTING (Continued)

(b) Type 2: Separate and unlatch 2 small arms
on end of clip (Fig. 47) and swing away from fuel
line.
(c) Slide latch clip toward fuel rail while lifting
with screwdriver.
(d) Insert special fuel line removal tool (Snap-On
number FIH 9055-1 or equivalent) into fuel line
(Fig. 48). 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.
(8) 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.
ROLLOVER VALVE
DESCRIPTION
Diesel Powered Engine:One rollover valve is
used. The rollover valve is located on the top of the
fuel tank module (Fig. 49). The valve may be serviced
separately.
Gasoline Powered Engines:If equipped with a
26 or 34 gallon fuel tank, two rollover valves are
used. One of the valves is permanently mounted to
the top of fuel tank (Fig. 50). If replacement of this
particular valve is necessary, the fuel tank must be
replaced. The other rollover valve is located on the
top of the fuel pump module (Fig. 50). This valve
may be serviced separately. If replacement is neces-
sary, refer to the Removal/Installation section of this
group.
If equipped with a 35 gallon fuel tank, two rollover
valves are used. Both valves are permanently
mounted to the top of fuel tank (Fig. 51). If replace-
ment is necessary, the fuel tank must be replaced.
Fig. 48 Fuel Line Disconnection Using Special Tool
1 - SPECIAL FUEL LINE TOOL
2 - FUEL LINE
3 - FUEL RAIL
Fig. 49 Rollover Valve LocationÐDiesel Powered
1 - AUXILIARY CAPPED FITTING
2 - FUEL PUMP MODULE
3 - FUEL SUPPLY/RETURN FITTINGS
4 - ELECTRICAL CONNECTOR
5 - LOCKNUT
6 - ROLLOVER VALVE
BR/BEFUEL DELIVERY - GASOLINE 14 - 25
QUICK CONNECT FITTING (Continued)

STANDARD PROCEDURES - CLEANING FUEL
SYSTEM PARTS
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.
STANDARD PROCEDURE - AIR BLEED
A certain amount of air becomes trapped in the
fuel system when fuel system components on the
supply and/or high-pressure side are serviced or
replaced. Primary air bleeding is accomplished using
the electric fuel transfer (lift) pump. If the vehicle
has been allowed to run completely out of fuel, the
fuel injectors must also be bled as the fuel injection
pumpis notself-bleeding (priming).
Servicing or replacing components on the fuel
return side will not require air bleeding.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE.
(1) Loosen, but do not remove, banjo bolt (test port
fitting) holding low-pressure fuel supply line to side
of fuel injection pump (Fig. 2). Place a shop towel
around banjo fitting to catch excess fuel.
The fuel transfer (lift) pump is self-priming: When
the key is first turned on (without cranking engine),
the pump operates for approximately 2 seconds and
then shuts off. The pump will also operate for up to
25 seconds after the starter is quickly engaged, and
then disengaged without allowing the engine to start.
The pump shuts off immediately if the key is on and
the engine stops running.
(2) Turn key to CRANK position and quickly
release key to ON position before engine starts. This
will operate fuel transfer pump for approximately 25
seconds.
(3) If fuel is not present at fuel supply line after
25 seconds, turn key OFF. Repeat previous step until
fuel is exiting at fuel supply line.(4) Tighten banjo bolt at fuel supply line to 24 N´m
(18 ft. lbs.) torque. Primary air bleeding is now com-
pleted.
(5) Attempt to start engine. If engine will not
start, proceed to following steps.If engine does
start, it may run erratically and be very noisy
for a few minutes. This is a normal condition.
(6)Continue to next step if:
²The vehicle fuel tank has been allowed to run
empty
²The fuel injection pump has been replaced
²High-pressure fuel lines have been replaced
²Vehicle has not been operated after an extended
period
CAUTION: Do not engage the starter motor for more
than 30 seconds at a time. Allow two minutes
between cranking intervals.
(7) Perform previous air bleeding procedure steps
using fuel transfer pump. Be sure fuel is present at
fuel supply line (Fig. 2) before proceeding.
(8) Crank the engine for 30 seconds at a time to
allow air trapped in the injection pump to vent out
the drain manifold.Fig. 2 Fuel Supply Line Banjo Bolt
1 - FUEL SUPPLY LINE
2 - FUEL RETURN LINE
3 - BANJO BOLT (TEST PORT FITTING)
4 - OVERFLOW VALVE
5 - BANJO FITTING
BR/BEFUEL DELIVERY - DIESEL 14 - 57
FUEL DELIVERY - DIESEL (Continued)

DESCRIPTIONÐFUEL PUMP 235 H.P.
The fuel injection pump is mounted to the rear of
the timing gear housing on the left side of engine
(Fig. 15).
OPERATION
The Bosch VP44 fuel injection pump (Fig. 16) is a
solenoid-valve controlled-radial-piston-distributor
type pump.
The injection pump is driven by the engine cam-
shaft. A gear on the end of the pump shaft meshes
with the camshaft gear. The pump is timed to the
engine. The VP44 is controlled by an integral (and
non-serviceable) Fuel Pump Control Module (FPCM)
(Fig. 15). The FPCM can operate the engine as an
engine controller if a Crankshaft Position Sensor
(CKP) signal is not present.
Fuel from the transfer (lift) pump enters the VP44
where it is pressurized and then distributed through
high-pressure lines to the fuel injectors. The VP44 is
cooled by the fuel that flows through it. A greater
quantity of fuel is required for cooling the VP44 than
what is necessary for engine operation. Because of
this, approximately 70 percent of fuel entering the
pump is returned to the fuel tank through the over-
flow valve and fuel return line. Refer to Overflow
Valve Description/Operation for additional informa-
tion.The VP44 is not self-priming. At least two fuel
injectors must be bled to remove air from the system.
When servicing the fuel system, disconnecting compo-
nents up to the pump will usually not require air
bleeding from the fuel system. However, removal of
the high-pressure lines, removal of the VP44 pump,
or allowing the vehicle to completely run out of fuel,
will require bleeding air from the high-pressure lines
at the fuel injectors.
VP44 timing is matched to engine timing by an off-
set keyway that fits into the pump shaft. This key-
way has a stamped number on it that is matched to
a number on the VP44 pump (each keyway is cali-
brated to each pump).
When removing/installing the VP44, the same
numbered keyway must always be installed.
Also, the arrow on the top of the keyway should
be installed pointed rearward towards the
pump.
Because of electrical control, the injection pump
high and low idle speeds are not adjustable. Also,
adjustment of fuel pump timing is not required and
is not necessary.
DIAGNOSIS AND TESTINGÐFUEL INJECTION
PUMP TIMING
With the Bosch VP44 injection pump, there are no
mechanical adjustments needed for fuel injection tim-
ing. All timing and fuel adjustments are made by the
Engine Control Module (ECM). However, if a Diag-
nostic Trouble Code (DTC) has been stored indicating
an ªengine sync errorº or a ªstatic timing errorº, per-
form the following.
Fig. 15 Fuel Injection Pump Location
1 - FPCM ELECTRICAL CONNECTOR
2 - HIGH-PRESSURE FUEL LINES
3 - FITTINGS
4 - FUEL INJECTION PUMP
5 - FPCM
Fig. 16 Bosch VP44 Fuel Injection Pump
1 - BOSCH VP44 PUMP
14 - 66 FUEL DELIVERY - DIESELBR/BE
FUEL INJECTION PUMP (Continued)

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
High-pressure lines are used between the fuel
injection pump and the fuel injectors only. 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: Refer to Cleaning Fuel System Parts.
(1) Disconnect both negative battery cables from
both batteries. Cover and isolate ends of cables.
(2) Thoroughly clean fuel lines at cylinder head
and injection pump ends.
(3) Remove cable cover (Fig. 39). Cable cover is
attached with 2 Phillips screws, 2 plastic retention
clips and 2 push tabs (Fig. 39). Remove 2 Phillips
screws and carefully pry out 2 retention clips. After
clip removal, push rearward on front tab, and
upward on lower tab for cover removal.Do not
remove any cables at lever.
(4) Disconnect wiring harness (clip) at bottom of
Accelerator Pedal Position Sensor (APPS) mounting
bracket (Fig. 40).(5) Using 2 small screwdrivers, pry front wiring
clip (Fig. 41) from cable bracket housing. Position
wiring harness towards front of engine.
Fig. 39 Cable/Lever/Throttle Linkage Cover
1 - CABLE/LEVER/LINKAGE COVER
2 - PUSH UP LOWER TAB
3 - SCREWS/CLIPS (2)
4 - TAB PUSH HERE
Fig. 40 Wiring Clip at APPS
1 - LEVER
2 - MOUNTING BOLTS (6)
3 - WIRE HARNESS CLIP
4 - CALIBRATION SCREWS (NO ADJUSTMENT)
5 - APPS ASSEMBLY
Fig. 41 Air Tube (Typical)
1 - ENGINE OIL DIPSTICK TUBE
2 - TUBE BOLT
3 - CLAMPS
4 - AIR TUBE (INTAKE MANIFOLD TO CHARGE AIR COOLER
5 - CABLE BRACKET HOUSING
6 - FRONT WIRING CLIP
7 - GROUND CABLE
8 - RUBBER HOSE
9 - AIR INTAKE HOUSING
BR/BEFUEL DELIVERY - DIESEL 14 - 75
FUEL LINES (Continued)