fuel tank removal DODGE RAM 2001 Service Owner's Manual

(2)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
top of fuel tank (Fig. 53). If replacement of this par-
ticular valve is necessary, fuel tank must be replaced.
Refer to Fuel Tank Removal/Installation in Group 14,
Fuel System. The other rollover valve is located on
top of fuel pump module (Fig. 53). This valve may be
serviced separately. Refer to following steps for pro-
cedures.
If equipped with a 35 gallon fuel tank, two rollover
valves are also used, but both valves are perma-
nently mounted to top of fuel tank (Fig. 54). If
replacement is necessary, fuel tank must be replaced.
Refer to Fuel Tank Removal/Installation in Group 14,
Fuel System.
(a) Disconnect negative battery cable at battery.
(b) Remove fuel filler cap and drain fuel tank.
(c) Remove fuel tank. Refer to Fuel Tank Remov-
al/Installation in Fuel System.
(d) Disconnect tube (line) at valve.
(e) The rollover valve is seated into a rubber
grommet. Remove valve by prying one side upward
and then roll valve out of grommet.
(f) Discard old grommet.
INSTALLATION
(1) Install new grommet into fuel pump (or fuel
tank) module.
(2) Using finger pressure only, press valve into
place.
(3) Install fuel tank. Refer to Fuel Tank Installa-
tion.
(4) Fill fuel tank. Install fuel tank filler cap.
(5) Connect negative battery cable(s).
(6) Start vehicle and check for leaks.
Fig. 53 Rollover Valve Locations - Gas Powered -
26/34 Gallon Tank
1 - FUEL FILTER/PRESSURE REGULATOR
2 - FUEL SUPPLY FITTING
3 - REAR ROLLOVER VALVE
4 - ELECTRICAL CONNECTOR
5 - FUEL PUMP MODULE
6 - FRONT ROLLOVER VALVE
7 - LOCKNUT
Fig. 54 Rollover Valve Locations - Gas Powered
with 35 Gallon Tank
1 - FRONT ROLLOVER VALVE
2 - FUEL PUMP MODULE
3 - REAR ROLLOVER VALVE
4 - FUEL TANK
BR/BEFUEL DELIVERY - GASOLINE 14 - 27
ROLLOVER VALVE (Continued)

FUEL DELIVERY - DIESEL
TABLE OF CONTENTS
page page
FUEL DELIVERY - DIESEL
DESCRIPTION...........................54
OPERATION.............................56
DIAGNOSIS AND TESTING.................56
AIR IN FUEL SYSTEM...................56
FUEL SUPPLY RESTRICTIONS............56
STANDARD PROCEDURE..................56
WATER DRAINING AT FUEL FILTER........56
CLEANING FUEL SYSTEM PARTS..........57
AIR BLEED............................57
SPECIFICATIONS........................58
SPECIAL TOOLS.........................59
FUEL FILTER / WATER SEPARATOR
DESCRIPTION...........................59
OPERATION.............................59
REMOVAL..............................60
INSTALLATION...........................61
FUEL HEATER
DESCRIPTION...........................62
OPERATION.............................62
DIAGNOSIS AND TESTING.................62
FUEL HEATER.........................62
REMOVAL..............................63
FUEL HEATER RELAY
DESCRIPTION...........................63
OPERATION.............................63
DIAGNOSIS AND TESTING.................64
FUEL HEATER RELAY...................64
REMOVAL..............................65
INSTALLATION...........................65
FUEL INJECTION PUMP
DESCRIPTION...........................65
OPERATION.............................66
DIAGNOSIS AND TESTING.................66
FUEL INJECTION PUMP TIMING...........66
REMOVAL..............................68
INSTALLATION...........................71
FUEL INJECTION PUMP DATA PLATE
SPECIFICATIONS........................73FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION...........................73
OPERATION.............................73
FUEL LINES
DESCRIPTION...........................73
OPERATION.............................74
DIAGNOSIS AND TESTING.................74
HIGH-PRESSURE FUEL LINE LEAK.........74
REMOVAL..............................75
INSTALLATION...........................77
FUEL TANK
DESCRIPTION...........................78
FUEL TANK MODULE
DESCRIPTION...........................78
OPERATION.............................78
REMOVAL..............................78
INSTALLATION...........................79
FUEL TRANSFER PUMP
DESCRIPTION...........................79
OPERATION.............................79
DIAGNOSIS AND TESTING.................80
FUEL TRANSFER PUMP PRESSURE........80
REMOVAL..............................83
INSTALLATION...........................83
OVERFLOW VALVE
DESCRIPTION...........................83
OPERATION.............................83
DIAGNOSIS AND TESTING.................84
OVERFLOW VALVE.....................84
REMOVAL..............................84
INSTALLATION...........................85
WATER IN FUEL SENSOR
DESCRIPTION...........................85
OPERATION.............................85
REMOVAL..............................85
FUEL DRAIN MANIFOLD
DESCRIPTION...........................86
OPERATION.............................86
REMOVAL..............................86
INSTALLATION...........................86
FUEL DELIVERY - DIESEL
DESCRIPTION - DIESEL FUEL DELIVERY
SYSTEM
The fuel system on the Cummins 24 valveÐTurbo
Diesel Engine uses anelectronicfuel injection
pump with three control modules.Also refer to the Powertrain Control Module (PCM)
or Engine Control Module sections.
Some fuel system components are shown in (Fig.
1).
The fuel delivery system consists of the:
²Accelerator pedal
²Air cleaner housing/element
²Fuel drain manifold (passage)
14 - 54 FUEL DELIVERY - DIESELBR/BE

²Fuel filter/water separator
²Fuel heater
²Fuel heater relay
²Fuel transfer (lift) pump
²Fuel injection pump
²Fuel injectors
²Fuel heater temperature sensor
²Fuel tank
²Fuel tank filler/vent tube assembly
²Fuel tank filler tube cap
²Fuel tank module containing the rollover valve,
fuel gauge sending unit (fuel level sensor) and a sep-
arate fuel filter located at bottom of tank module
²Fuel tubes/lines/hoses
²High-pressure fuel injector lines
²In-tank fuel filter (at bottom of fuel tank mod-
ule)
²Low-pressure fuel supply lines
²Low-pressure fuel return line
²Overflow valve
²Quick-connect fittings
²Throttle cable
²Water draining
OPERATION
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 120,000 KPA (17,405
PSI). 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 - AIR IN FUEL
SYSTEM
Air will enter the fuel system whenever fuel supply
lines, separator filters, injection pump, high-pressure
lines or injectors are removed or disconnected. Air
trapped in the fuel system can result in hard start-
ing, a rough running engine, engine misfire, low
power, excessive smoke and fuel knock. After service
is performed, air must be bled from the system
before starting the engine.Inspect the fuel system from the fuel transfer
pump to the injectors for loose connections. Leaking
fuel is an indicator of loose connections or defective
seals. Air can also enter the fuel system between the
fuel tank and the transfer pump. Inspect the fuel
tank and fuel lines for damage that might allow air
into the system.
For air bleeding, refer to the Air Bleed Procedure.
DIAGNOSIS AND TESTING - FUEL SUPPLY
RESTRICTIONS
LOW-PRESSURE LINES
Fuel supply line restrictions or a defective fuel
transfer pump can cause starting problems and pre-
vent engine from accelerating. The starting problems
include; low power and/or white fog like exhaust.
Test all fuel supply lines for restrictions or block-
age. Flush or replace as necessary. Bleed fuel system
of air once a fuel supply line has been replaced. Refer
to Air Bleed Procedure for procedures.
To test for fuel line restrictions, a vacuum restric-
tion test may be performed. Refer to Fuel Transfer
Pump Pressure Test.
HIGH-PRESSURE LINES
Restricted (kinked or bent) high-pressure lines can
cause starting problems, poor engine performance,
engine mis-fire and white smoke from exhaust.
Examine all high-pressure lines for any damage.
Each radius on each high-pressure line must be
smooth and free of any bends or kinks.
Replace damaged, restricted or leaking high-pres-
sure fuel lines with correct replacement line.
CAUTION: All high-pressure fuel lines must be
clamped securely in place in holders. 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 line is kinked or bent, it
must be replaced. Use only recommended lines
when replacement of high-pressure fuel line is nec-
essary.
STANDARD PROCEDURES - WATER DRAINING
AT FUEL FILTER
Refer to Fuel Filter/Water Separator removal/in-
stallation for procedures.
14 - 56 FUEL DELIVERY - DIESELBR/BE
FUEL DELIVERY - DIESEL (Continued)

SPECIAL TOOLS
DIESEL FUEL SYSTEMFUEL FILTER / WATER
SEPARATOR
DESCRIPTION
The fuel filter/water separator assembly is located
on left side of engine above starter motor (Fig. 4).
The assembly also includes the fuel heater and
Water-In-Fuel (WIF) sensor.
OPERATION
The fuel filter/water separator protects the fuel
injection pump by removing water and contaminants
from the fuel. The construction of the filter/separator
allows fuel to pass through it, but helps prevent
moisture (water) from doing so. Moisture collects at
the bottom of the canister.
Refer to the maintenance schedules for the recom-
mended fuel filter replacement intervals.
For draining of water from canister, refer to Fuel
Filter/Water Separator Removal/Installation section.
A Water-In-Fuel (WIF) sensor is attached to side of
canister. Refer to Water-In-Fuel Sensor Description/
Operation.
The fuel heater is installed into the top of the fil-
ter/separator housing. Refer to Fuel Heater Descrip-
tion/Operation.
Spanner Wrench (Fuel Tank Module Removal/
Installation)Ð6856
Engine Barring (Rotating ) ToolÐ7471B (also part of
Kit #6860)
Fuel Injector Pop Pressure AdaptorÐ8301
Fuel Injector RemoverÐ8318
Fuel Injector Tube (Connector) RemoverÐ8324
Fig. 4 Fuel Filter/Water Separator Location
1 - FUEL HEATER AND TEMP. SENSOR
2 - FUEL FILTER/WATER SEPARATOR
3 - FUEL HEATER ELECTRICAL CONNECTOR
BR/BEFUEL DELIVERY - DIESEL 14 - 59
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)

(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)

(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)

If a Diagnostic Trouble Code (DTC) has been stored
for ªdecreased engine performance due to high injec-
tion pump fuel temperatureº, the overflow valve may
be stuck in closed position.
DIAGNOSIS AND TESTING - OVERFLOW VALVE
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 is
located on the side of the injection pump (Fig. 59). It
is also used to connect the fuel return line (banjo fit-
ting) to the fuel injection pump. The valve opens at
approximately 97 kPa (14 psi). If the check valve
within the assembly is sticking, low engine power or
hard starting may result.
If a Diagnostic Trouble Code (DTC) has been stored
for ªdecreased engine performance due to high injec-
tion pump fuel temperatureº, the overflow valve may
be stuck in closed position.
A rubber tipped blow gun with regulated air line
pressure is needed for this test.
(1) Clean area around overflow valve and fuel
return line at injection pump before removal.(2) Remove valve from pump and banjo fitting.
(3) Discard old sealing gaskets.
(4) Set regulated air pressure to approximately 97
kPa (14±16 psi).
(5) Using blow gun, apply pressure to overflow
valve inlet end (end that goes into injection pump).
(6) Internal check valve should release, and air
should pass through valve at 97 kPa (14±16 psi). If
not, replace valve.
(7) Reduce regulated air pressure to 10 psi and
observe valve. Valve should stay shut. If not, replace
valve.
(8) Install new sealing gaskets to valve.
(9) Install valve through banjo fitting and into
pump.
(10) Tighten to 30 N´m (24 ft. lbs.) torque.
REMOVAL
The overflow valve (pressure relief valve) is located
at the outside of fuel injection pump (Fig. 60). It con-
nects the fuel return line (banjo fitting) to the pump.
The valve has no internal serviceable parts and must
be replaced as an assembly. Two sealing gaskets are
used. One gasket is located between pump and banjo
fitting. The other is located between the banjo fitting
and end of valve.
Fig. 58 Overflow Valve Location
1 - FUEL SUPPLY LINE
2 - FUEL RETURN LINE
3 - BANJO BOLT (TEST PORT FITTING)
4 - OVERFLOW VALVE
5 - BANJO FITTING
Fig. 59 Overflow Valve Location
1 - FUEL SUPPLY LINE
2 - FUEL RETURN LINE
3 - BANJO BOLT (TEST PORT FITTING)
4 - OVERFLOW VALVE
5 - BANJO FITTING
14 - 84 FUEL DELIVERY - DIESELBR/BE
OVERFLOW VALVE (Continued)