DODGE RAM 2001 Service Repair Manual

the fuel injection pump and the fuel injectors. Also
refer to High-Pressure Fuel Lines Description/Opera-
tion.
DESCRIPTIONÐHIGH PRESSURE FUEL LINES
The high-pressure fuel lines are the 6 lines located
between the fuel injection pump and the fuel injector
connector tubes (Fig. 37). All other fuel lines are con-
sidered low-pressure lines.
OPERATIONÐHIGH PRESSURE FUEL LINES
CAUTION: The high-pressure fuel lines must be
held securely in place in their 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. If lines are ever
kinked or bent, they must be replaced. Use only the
recommended lines when replacement of high-pres-
sure fuel line is necessary.
High-pressure fuel lines deliver fuel under pres-
sure of up to approximately 120,000 kPa (17,405 PSI)
from the injection pump to the fuel injectors. The
lines expand and contract from the high-pressure
fuel pulses generated during the injection process. 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 opera-
tion.
WARNING: USE EXTREME CAUTION WHEN
INSPECTING FOR HIGH-PRESSURE FUEL LEAKS.
INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH
A SHEET OF CARDBOARD. HIGH FUEL INJECTIONPRESSURE 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 120,000 kPa (17,400 PSI), USE EXTREME
CAUTION WHEN INSPECTING FOR HIGH-PRES-
SURE FUEL LEAKS. DO NOT GET YOUR HAND
NEAR A SUSPECTED LEAK. INSPECT FOR HIGH-
PRESSURE FUEL LEAKS WITH A SHEET OF CARD-
BOARD. HIGH FUEL INJECTION PRESSURE CAN
CAUSE PERSONAL INJURY IF CONTACT IS MADE
WITH THE SKIN.
Start the engine. Move the cardboard over the
high-pressure fuel lines and check for fuel spray onto
the cardboard (Fig. 38). If a high-pressure line con-
nection is leaking, bleed the system and tighten the
connection. Refer to the Air Bleed Procedure in this
group for procedures. Replace damaged, restricted or
leaking high-pressure fuel lines with the correct
replacement line.
Fig. 37 High-Pressure Fuel Lines
Fig. 38 Typical Test for Leaks with Cardboard
1 - HIGH-PRESSURE LINE
2 - CARDBOARD
3 - FITTING
14 - 74 FUEL DELIVERY - DIESELBR/BE
FUEL LINES (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)

(6) Remove electrical connector from APPS by
pushing connector tab rearward while pulling down
on connector (Fig. 42).
(7) Disconnect 2 electrical cables from cable
mounting studs (Fig. 43) at intake air heater on top
of intake manifold.
(8) Remove engine oil dipstick from engine.
(9) Remove engine oil dipstick tube support
mounting bolt (Fig. 43) and position tube to side.
(10) Disconnect clamps and remove air tube
(intake manifold-to-intercooler) (Fig. 41).
(11) Remove 4 air intake housing mounting bolts
and remove housing (Fig. 44) and (Fig. 43). Position
ground cable at top of air intake housing to front of
engine.
(12) Remove intake manifold air heater element
block from engine (Fig. 45). Discard old upper and
lower gaskets
(13) Remove 3 cable bracket housing mounting
bolts (Fig. 44). Carefully position cable bracket and
cable assembly to side of engine.Leave cables con-
nected to lever.
(14) Remove engine lifting bracket at rear of
intake manifold (2 bolts) (Fig. 46).
(15) Remove bolts from all fuel injection line sup-
port brackets at intake manifold.
(16) Place shop towels around fuel lines at fuel
injectors. Do not allow fuel to drip down side of
engine.
Fig. 42 Rear View of APPS
1 - APPS
2-TAB
3 - PUSH FOR REMOVAL
4 - APPS CONNECTOR
Fig. 43 Air Intake Housing (Rear View)
1 - TUBE MOUNTING BOLT
2 - HOUSING BOLTS (2)
3 - INTAKE HEATER CABLE MOUNTING STUDS (2)
4 - DIPSTICK TUBE
Fig. 44 Air Intake Housing (Front View)
1 - GROUND CABLE BOLT
2 - INTAKE AIR HOUSING
3 - CABLE BRACKET HOUSING BOLTS (3)
4 - GROUND CABLE
14 - 76 FUEL DELIVERY - DIESELBR/BE
FUEL LINES (Continued)

CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE FITTINGS AT INJECTION PUMP,
USE A BACK-UP WRENCH ON DELIVERY VALVE AT
PUMP. DO NOT ALLOW DELIVERY VALVE TO
ROTATE.
(17) Loosen high-pressure line fittings at injection
pump (Fig. 47) beginning with cylinders 1, 2 and 4.
(18) Loosen high-pressure lines at cylinder head
for cylinders 1, 2 and 4 (Fig. 46).(19) Carefully remove front line bundle from
engine.Do not bend lines while removing.While
removing front line bundle, note line position.
(20) Loosen high-pressure lines at injection pump
beginning with cylinders 3, 5 and 6.
(21) Loosen high-pressure lines at cylinder head
for cylinders 3, 5 and 6 (Fig. 46).
(22) Carefully remove rear line bundle from
engine.Do not bend lines while removing.While
removing rear line bundle, note line position.
INSTALLATION
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: Be sure that the high-pressure fuel lines
are installed in the same order that they were
removed.
(1) Lubricate threads of injector line fittings with
clean engine oil.
(2) Loosen, but do not remove, all fuel line support
bracket bolts.
Fig. 45 Intake Manifold Air Heater (Elements)
1 - AIR HEATER ELEMENTS
2 - LOWER GASKET
3 - BLOCK
4 - UPPER GASKET
Fig. 46 High-Pressure Fuel Lines
Fig. 47 High Pressure Lines at Fuel Injection Pump
1 - FPCM ELECTRICAL CONNECTOR
2 - HIGH-PRESSURE FUEL LINES
3 - FITTINGS
4 - FUEL INJECTION PUMP
5 - FPCM
BR/BEFUEL DELIVERY - DIESEL 14 - 77
FUEL LINES (Continued)

(3) Installrearinjection line bundle beginning
with cylinder head (fuel injector) connections, fol-
lowed by injection pump connections. Tighten all fit-
tings finger tight.
(4) Tighten fittings at fuel injector ends for cylin-
ders number 6 and 5 to 38 N´m (28 ft. lbs.) torque.
Do not tighten number 3 line at this time. It
will be tightened during bleeding procedure.
(5) Tighten 3 fittings at fuel injection pump ends
to 24 N´m (18 ft. lbs.) torque.
(6) Installfrontinjection line bundle beginning
with cylinder head (fuel injector) connections, fol-
lowed by injection pump connections. Tighten all fit-
tings finger tight.
(7) Tighten fitting at fuel injector end for cylinder
number 2 to 38 N´m (28 ft. lbs.) torque.Do not
tighten lines number 1 or 4 at this time. They
will be tightened during bleeding procedure.
(8) Tighten remaining 3 fittings at fuel injection
pump ends to 24 N´m (18 ft. lbs.) torque.
(9) Install fuel line support bracket bolts to intake
manifold and tighten to 24 N´m (18 ft. lbs.) torque.
CAUTION: Be sure fuel lines are not contacting
each other or any other component. Noise will
result.
(10) Install engine lifting bracket at rear of intake
manifold. Tighten 2 bolts to 77 N´m (57 ft. lbs.)
torque.
(11) Install cable bracket housing/cable assembly
and tighten 3 mounting bolts to 24 N´m (18 ft. lbs.)
torque.
(12) Clean any old gasket material below and
above intake manifold air heater element block. Also
clean mating areas at intake manifold and air intake
housing.
(13) Using new gaskets, position intake manifold
air heater element block to engine.
(14) Install air intake housing and position ground
cable. Install 4 mounting bolts and tighten to 24 N´m
(18 ft. lbs.) torque.
(15) Install air tube (intake manifold-to-charge air
cooler) (Fig. 41). Tighten clamps to 8 N´m (72 in. lbs.)
torque.
(16) Install engine oil dipstick tube support mount-
ing bolt and tighten to 24 N´m (18 ft. lbs.) torque.
(17) Install engine oil dipstick to engine.
(18) Connect 2 electrical cables to cable mounting
studs.
(19) Connect electrical connector to bottom of
APPS by pushing connector upward until it snaps
into position.
(20) Connect wiring harness (clip) at bottom of
Accelerator Pedal Position Sensor (APPS) mounting
bracket (Fig. 40).(21) Connect front wiring clip (Fig. 41) to cable
bracket housing.
(22) Install cable cover (Fig. 39).
(23) Connect both negative battery cables to both
batteries.
(24) Bleed air from fuel system. Do this at fuel
injector ends of lines. Use cylinders numbers 1, 3 and
4 for bleeding . (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE). After
bleeding, tighten fittings to 38 N´m (28 ft. lbs.)
torque.
(25) Check lines/fittings for leaks.
FUEL TANK
DESCRIPTION - DIESEL FUEL TANK
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.
For removal and installation procedures, refer to
Fuel Tank - Gasoline Engines.
FUEL TANK MODULE
DESCRIPTION
An electric fuel pump isnot usedin the fuel tank
module for diesel powered engines. Fuel is supplied
by the engine mounted fuel transfer pump and the
fuel injection pump.
The fuel tank module is installed in the top of the
fuel tank (Fig. 48). The fuel tank module (Fig. 48)
contains the following components:
²Fuel reservoir
²A separate in-tank fuel filter
²Rollover valve
²Fuel gauge sending unit (fuel level sensor)
²Fuel supply line connection
²Fuel return line connection
²Auxiliary non-pressurized fuel supply fitting
OPERATION
Refer to Fuel Gauge Sending Unit.
REMOVAL
(1) Drain and remove fuel tank. Refer to Fuel
Tank Removal/Installation.
(2) Thoroughly clean area around tank module at
top of tank.
14 - 78 FUEL DELIVERY - DIESELBR/BE
FUEL LINES (Continued)

(3) The plastic fuel tank module locknut is
threaded onto fuel tank (Fig. 39). Install Special Tool
6856 to locknut and remove locknut (Fig. 49). The
fuel tank module will spring up when locknut is
removed.
(4) Remove module from fuel tank.
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 arrow at top of module should be aligned
between two marks stamped into tank (approximate-
ly 2 o'clock position). The fuel line connectors, roll
over valve and fuel gauge electrical connector should
all be pointed to drivers side of vehicle. Rotate and
align module/tank marks 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 located
on the left-rear side of the engine cylinder block
above the starter motor (Fig. 50). The 12±volt electric
vane-type pump is operated and controlled by the
Engine Control Module (ECM) (Fig. 51).
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.
Normal current flow to the pump is 12 amperes.
With the engine running, the pump has2modes of
operation: Mode 1: 100 percent duty-cycle with a
minimum pressure of 10 psiexcept when the
engine is cranking.Mode 2: 25 percent duty-cycle
with minimum pressure of 7 psiwith the engine
cranking
The 25 percent duty-cycle is used to limit injection
pump inlet pressure until the engine is running.
Fig. 48 Top View of Fuel Tank ModuleÐDiesel
1 - AUXILIARY CAPPED FITTING
2 - FUEL PUMP MODULE
3 - FUEL SUPPLY/RETURN FITTINGS
4 - ELECTRICAL CONNECTOR
5 - LOCKNUT
6 - ROLLOVER VALVE
Fig. 49 Locknut Removal/InstallationÐTYPICAL
MODULE
1 - SPECIAL TOOL 6856
2 - LOCKNUT
BR/BEFUEL DELIVERY - DIESEL 14 - 79
FUEL TANK MODULE (Continued)

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. The valve is located
on the side of the injection pump (Fig. 52). It is also
used to connect the fuel return line to the side of the
injection pump. This valve opens at approximately 97
kPa (14 psi) and returns fuel to the fuel tank
through the fuel return line.
DIAGNOSIS AND TESTING - FUEL TRANSFER
PUMP PRESSURE
The following tests will include: pressures
tests of fuel transfer pump (engine running and
engine cranking), a pressure drop test of fuel
filter, a test for supply side restrictions, and a
test for air in fuel supply side.
Fig. 50 Fuel Transfer Pump Location
1 - OIL PRESSURE SENSOR
2 - PUMP BRACKET NUTS (3)
3 - SUPPORT BRACKET BOLT
4 - BANJO BOLT (REAR)
5 - FUEL SUPPLY LINE
6 - ELECTRICAL CONNECTOR
7 - BANJO BOLT (FRONT)
8 - FUEL TRANSFER PUMP
Fig. 51 Engine Control Module (ECM) Location
1 - ENGINE CONTROL MODULE (ECM)
2 - HEX HEADED BOLT
3 - 50-WAY CONNECTOR
4 - FUEL TRANSFER PUMP
5 - MOUNTING BOLTS (3)
Fig. 52 Injection Pump Overflow Valve Location
1 - FUEL SUPPLY LINE
2 - FUEL RETURN LINE
3 - BANJO BOLT (TEST PORT FITTING)
4 - OVERFLOW VALVE
5 - BANJO FITTING
14 - 80 FUEL DELIVERY - DIESELBR/BE
FUEL TRANSFER PUMP (Continued)

Refer to Fuel Transfer Pump Description/Operation
for an operational description of transfer pump.
The fuel transfer (lift) pump is located on left side
of engine and above starter motor (Fig. 53).
An improperly operating fuel transfer pump, a
plugged or dirty fuel filter, or a defective overflow
valve can cause low engine power, excessive white
smoke and/or hard engine starting.
Before performing following tests, inspect fuel sup-
ply and return lines for restrictions, kinks or leaks.
Fuel leaking from pump casing indicates a leaking
pump which must be replaced.
Pressure Test:Because the transfer pump is oper-
ating at two different pressure cycles (engine running
and engine cranking), two different pressure tests
will be performed.
(1) Remove protective cap at inlet test port (Fig.
54). Clean area around cap/fitting before cap
removal.
(2) Remove protective cap at outlet test port (Fig.
55). Clean area around cap/fitting before cap
removal.
(3) Install Special Fuel Pressure Test Gauge 6828
(or equivalent) to fitting at inlet test port (Fig. 54).(4) To prevent engine from starting, remove fuel
system relay (fuel injection pump relay). Relay is
located in Power Distribution Center (PDC). Refer to
label under PDC cover for relay location.
Fig. 53 Fuel Transfer Pump Location
1 - OIL PRESSURE SENSOR
2 - PUMP BRACKET NUTS (3)
3 - SUPPORT BRACKET BOLT
4 - BANJO BOLT (REAR)
5 - FUEL SUPPLY LINE
6 - ELECTRICAL CONNECTOR
7 - BANJO BOLT (FRONT)
8 - FUEL TRANSFER PUMP
Fig. 54 Fuel Pressure Test Port Fitting (Inlet)
1 - FUEL PRESSURE TEST PORT (INLET)
2 - FUEL FILTER/WATER SEPARATOR
Fig. 55 Fuel Pressure Test Port Fitting (Outlet)
1 - FUEL PRESSURE TEST PORT (OUTLET)
BR/BEFUEL DELIVERY - DIESEL 14 - 81
FUEL TRANSFER PUMP (Continued)

(5) Using key, crank engine over while observing
gauge. Pressure should be 5±7 psi.
(6) Re-install fuel system relay to PDC.
(7) Start engine and record fuel pressure. Pressure
should be aminimumof 69 kPa (10 psi) at idle
speed.
(8) Because fuel pump relay was removed, a Diag-
nostic Trouble Code (DTC) may have been set. After
testing is completed, and relay has been installed,
use DRB scan tool to remove DTC.
Pressure Drop Test:
(9) Shut engine off and remove test gauge from
inlet port test fitting. Re-attach 6828 test gauge to
outlet port (Fig. 55). Start engine and record fuel
pressure. Pressure should not be more than 34 kPa
(5 psi) lower than inlet port pressure test. If so,
replace fuel filter.
Fuel Supply Restriction Test:
Due to very small vacuum specifications, the DRB
scan tool along with the Periphal Expansion Port
(PEP) Module and 0±15 psi transducer must be used.
(10) Verify transfer pump pressure is OK before
performing restriction test.
(11) Locate and disconnect fuel supply line quick-
connect fitting at left-rear of engine (Fig. 56). After
disconnecting line, plastic clip will remain attached
to metal fuel line at engine. Carefully remove clip
from metal line. Snap same clip into fuel supply
hose.
(12) Install Special Rubber Adapter Hose Tool
6631 (3/8º) into ends of disconnected fuel supply line.(13) Install transducer from PEP module to brass
ªTº fitting on tool 6631.
(14) Hook up DRB scan tool to transducer.
WARNING: DO NOT STAND IN LINE WITH THE
COOLING FAN FOR THE FOLLOWING STEPS.
(15) Start engine and record vacuum reading with
engine speed at high-idle (high-idle means engine
speed is at 100 percent throttle and no load). The
fuel restriction testMUSTbe done with engine speed
at high-idle.
(16) If vacuum reading islessthan 6 in/hg. (0±152
mm hg.), test is OK. If vacuum reading ishigher
than 6 in/hg. (152 mm hg.), restriction exists in fuel
supply line or in fuel tank module. Check fuel supply
line for damage, dents or kinking. If OK, remove
module and check module and lines for blockage.
Also check fuel pump inlet filter at bottom of module
for obstructions.
Testing For Air Leaks in Fuel Supply Side:
(17) A 3±foot section of 3/8º I.D. clear tubing is
required for this test.
(18) Using a tire core valve removal tool, carefully
remove core valve from inlet fitting test port.
(19) Attach and clamp the 3/8ºclear hose to fitting
nipple.
(20) Place other end of hose into a large clear con-
tainer. Allow hose to loop as high as possibleabove
test port.
(21) The fuel transfer pump can be put into a 25
second run (test) mode if key is quickly turned to
crank position and released back to run position
without starting engine.
To prevent engine from starting in this test, first
remove fuel system relay (fuel injection pump relay).
Relay is located in Power Distribution Center (PDC).
Refer to label under PDC cover for relay location.
Because fuel pump relay was removed, a Diagnos-
tic Trouble Code (DTC) may have been set. After test-
ing is completed, and relay has been installed, use
DRB scan tool to remove DTC.
(22) Allow air to purge from empty hose before
examining for air bubbles. Air bubbles should not be
present.
(23) If bubbles are present, check for leaks in sup-
ply line to fuel tank.
(24) If supply line is not leaking, remove fuel tank
module and remove filter at bottom of module (filter
snaps to module). Check for leaks between supply
nipple at top of module, and filter opening at bottom
of module. Replace module if necessary.
(25) After performing test, install core back into
test fitting. Before installing protective cap, be sure
fitting is not leaking.
Fig. 56 Fuel Return and Supply Line Quick-Connect
Locations
1 - FUEL RETURN LINE
2 - QUICK-CONNECT FITTINGS
3 - FUEL SUPPLY LINE
14 - 82 FUEL DELIVERY - DIESELBR/BE
FUEL TRANSFER PUMP (Continued)

REMOVAL
The fuel transfer pump (fuel lift pump) is located
on left side of engine, below and rearward of fuel fil-
ter (Fig. 57).
(1) Disconnect both negative battery cables at both
batteries.
(2) Thoroughly clean area around transfer pump
and fuel lines of any contamination.
(3) Remove starter motor. Refer to Starter Remov-
al/Installation in 8, Starting System for procedures.
(4) Place a drain pan below the pump.
(5) Disconnect fuel line quick-connect fitting at
fuel supply line (Fig. 57) at rear of pump.
(6) Remove support bracket bolt at top of pump
(Fig. 57).
(7) Remove front and rear banjo bolts at pump
(Fig. 57).
(8) Disconnect electrical connector at side of pump
(Fig. 57).
(9) Remove three pump bracket nuts (Fig. 57) and
remove pump from vehicle.
INSTALLATION
The fuel transfer pump (fuel lift pump) is located
on left side of engine, below and rearward of fuel fil-
ter (Fig. 57).
(1) Install new gaskets to fuel supply line/support
bracket and banjo bolt at rear of pump. Install line
and banjo bolt to pump.Do nottighten banjo bolt at
this time.
(2) Install new gaskets to fuel line and banjo bolt
at front of pump.
(3) Position 3 pump studs into pump mounting
bracket and install 3 nuts.Do nottighten nuts at
this time.
(4) Install support bracket bolt (Fig. 57).Do not
tighten bolt at this time.
(5) Tighten 3 pump nuts to 12 N´m (9 ft. lbs.)
torque.
(6) Tighten both banjo bolts to 24 N´m (18 ft. lbs.)
torque.
(7) Tighten support bracket bolt 12 N´m (9 ft. lbs.)
torque.
(8) Connect electrical connector to pump (Fig. 57).
(9) Connect fuel line quick-connect fitting to fuel
supply line at rear of pump.
(10) Install starter motor. Refer to Starter Remov-
al/Installation in 8, Starting for procedures.
(11) Connect both negative battery cables at both
batteries.
(12) Bleed air at fuel supply line at side of fuel
injection pump. Refer to the Air Bleed Procedure.
(13) Start engine and check for leaks.
OVERFLOW VALVE
DESCRIPTION
The overflow valve is located on the side of the
injection pump (Fig. 58). It is also used to connect
the fuel return line (banjo fitting) to the fuel injection
pump.
OPERATION
Fuel volume from the fuel transfer (lift) pump will
always provide more fuel than the fuel injection
pump requires. The overflow valve (a check valve) is
used to route excess fuel through the fuel return line
and back to the fuel tank. Approximately 70% of sup-
plied fuel is returned to the fuel tank. The valve
opens at approximately 97 kPa (14 psi). If the check
valve within the assembly is sticking open, fuel
drainage of the injection pump could cause hard
starting.
Fig. 57 Fuel Transfer Pump Location
1 - OIL PRESSURE SENSOR
2 - PUMP BRACKET NUTS (3)
3 - SUPPORT BRACKET BOLT
4 - BANJO BOLT (REAR)
5 - FUEL SUPPLY LINE
6 - ELECTRICAL CONNECTOR
7 - BANJO BOLT (FRONT)
8 - FUEL TRANSFER PUMP
BR/BEFUEL DELIVERY - DIESEL 14 - 83
FUEL TRANSFER PUMP (Continued)