wheel DODGE RAM 2001 Service Repair Manual

CAUTION: The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks. The crankshaft and seal sur-
faces must be completely dry when the seal is
installed. Use a soap and water solution on outside
diameter of seal to ease assembly.
(4) Make sure the provided seal pilot is installed
into the new crankshaft seal. Use the alignment/in-
stallation tool and press the seal onto the crankshaft
(Fig. 113). Alternately drive the seal at the 12, 3, 6
and 9 o'clock positions.
(5) Remove the alignment tool and trim the
retainer gasket even with the oil pan mounting sur-
face (Fig. 114).
(6) Remove the seal pilot.
(7) Apply a small amount of MopartSilicone Rub-
ber Adhesive Sealant to the oil pan rail T-joints.
(8) Install the oil pan, suction tube and gaskets
(Refer to 9 - ENGINE/LUBRICATION/OIL PAN -
INSTALLATION).
(9) Install the flywheel housing and bolts. Tighten
the bolts to 60 N´m (44 ft. lbs.) torque.
(10)
Install the starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - INSTALLATION).
(11) Install the flywheel or converter drive plate.
Tighten bolts to 137 N´m (101 ft. lbs.)
(12) Install the transmission and transfer case (if
equipped).
(13) Lower vehicle.
(14) Fill the crankcase with new engine oil.
(15) Connect the battery negative cables.
(16) Start engine and check for oil leaks.
SOLID LIFTERS/TAPPETS
REMOVAL
NOTE: This procedure requires use of Miller Tool
8502 Tappet Replacement Kit, or Cummins Tool Kit
#3822513.
(1) Remove camshaft (Refer to 9 - ENGINE/EN-
GINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
(2) Insert the trough (provided with tool kit) the
full length of the camshaft bore (Fig. 115). Make sure
the cap end goes in first and the open side faces up
(towards tappets).
Fig. 115 Inserting the Trough
1 - TROUGH
Fig. 113 Installing Seal Using Alignment Tool and
Hammer
1 - SEAL PILOT TOOL
2 - INSTALLATION TOOL
3 - SEAL
4 - RETAINER
Fig. 114 Trimming Excess Gasket Material
1 - GASKET
9 - 280 ENGINE 5.9L DIESELBR/BE
CRANKSHAFT REAR OIL SEAL RETAINER (Continued)

²Milky discoloration indicates coolant dilution.
(4) Clean the area around the oil filter head.
Remove the filter (Refer to 9 - ENGINE/LUBRICA-
TION/OIL FILTER - REMOVAL).
(5) Install new oil filter (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION).
(6) Clean the drain plug and the sealing surface of
the pan. Check the condition of the threads and seal-
ing surface on the oil pan and drain plug.
(7) Install the drain plug. Tighten the plug to 60
N´m (44 ft. lbs.) torque.
(8) Use only High-Quality Multi-Viscosity lubricat-
ing oil in the Cummins Turbo Diesel engine. Choose
the correct oil for the operating conditions (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(9) Fill the engine with the correct grade of new oil
(Refer to LUBRICATION & MAINTENANCE/FLUID
CAPACITIES - SPECIFICATIONS).
(10) Start the engine and operate it at idle for sev-
eral minutes. Check for leaks at the filter and drain
plug.
(11) Stop engine. Wait several minutes to allow the
oil to drain back to the pan and check the level
again.
USED ENGINE OIL DISPOSAL Care should be
exercised when disposing of used engine oil after
it has been drained from a vehicle's engine.
OIL COOLER & LINES
CLEANING AND INSPECTION
Clean the sealing surfaces.
Apply 483 kPa (70 psi) air pressure to the element
to check for leaks. If the element leaks, replace the
element.
OIL FILTER
REMOVAL
(1) Clean the area around the oil filter head.
Remove the filter using a 90-95 mm filter wrench.
(2) Clean the gasket surface of the filter head. The
filter canister O-Ring seal can stick on the filter
head. Make sure it is removed.
INSTALLATION
(1) Fill the oil filter element with clean oil before
installation. Use the same type oil that will be used
in the engine.
(2) Apply a light film of lubricating oil to the seal-
ing surface before installing the filter.CAUTION: Mechanical over-tightening may distort
the threads or damage the filter element seal.
(3) Install the filter until it contacts the sealing
surface of the oil filter adapter. Tighten filter an
additional ó turn.
OIL PAN
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Remove transmission and transfer case (if
equipped).
(4) Remove flywheel.
(5) Disconnect starter cables from starter motor.
(6) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
and transmission adapter plate assembly.
WARNING: HOT OIL CAN CAUSE PERSONAL
INJURY.
(7) Drain the engine oil (Refer to 9 - ENGINE/LU-
BRICATION/OIL - STANDARD PROCEDURE).
(8) Install the oil pan drain plug with a new seal-
ing washer and tighten to 60 N´m (44 ft. lbs.) torque.
(9) Remove oil pan bolts, break the pan to block
seal, and lower pan slightly and remove oil suction
tube fasteners.
(10) Remove oil pan and suction tube (Fig. 151).
Fig. 151 Oil Pan, Suction Tube and Gasket
1 - GASKET
2 - SUCTION TUBE
3 - OIL PAN
9 - 296 ENGINE 5.9L DIESELBR/BE
OIL (Continued)

CLEANING
Remove all gasket material from the oil pan and
cylinder block sealing surfaces. Extra effort may be
required around T-joint areas. Clean oil pan and
flush suction tube with a suitable solvent.
INSPECTION
Inspect the oil pan, suction tube, and tube braces
for cracks and damage. Replace any defective compo-
nent. Inspect the oil drain plug and drain hole
threads. Inspect the oil pan sealing surface for
straightness. Repair any minor imperfections with a
ball-peen hammer. Do not attempt to repair an oil
pan by welding.
INSTALLATION
(1) Fill the T-joint between the pan rail/gear hous-
ing and pan rail/rear seal retainer with sealant. Use
MopartSilicone Rubber Adhesive Sealant or equiva-
lent.
(2) Place suction tube in oil pan and guide them
into place (Fig. 151). Using a new tube to oil pump
gasket, install and tighten the suction tube bolts by
hand. Starting with the oil pump inlet bolts, tighten
the bolts to 24 N´m (18 ft. lbs.) torque. Tighten the
remaining tube brace bolts to 24 N´m (18 ft. lbs.)
torque.
(3) Starting in the center and working outward,
tighten the oil pan bolts to 24 N´m (18 ft. lbs.)
torque.
(4) Install the flywheel housing assembly with the
starter motor attached and tighten bolts to 60 N´m
(44 ft. lbs.) torque.
(5) Connect starter motor cables.
(6) Install transmission and transfer case (if
equipped).
(7) Lower vehicle.
(8) Install battery negative cables.
(9) Fill the crankcase with new engine oil.
(10) Start engine and check for leaks. Stop engine,
check oil level, and adjust, if necessary.
OIL PRESSURE RELIEF VALVE
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the threaded plug, spring and plunger
(Fig. 152). Insert a finger or a seal pick to lift the
plunger from the bore.
NOTE: If the plunger is stuck in the bore, it will be
necessary to remove the filter head.
CLEANING
(1) Clean the regulator spring and plunger with a
suitable solvent and blow dry with compressed air. If
the plunger bore requires cleaning, it is necessary to
remove the oil filter head to avoid getting debris into
the engine.
INSPECTION
Inspect the plunger and plunger bore for cracks
and excessive wear. Polished surfaces are acceptable.
Verify that the plunger moves freely in the bore.
Check the spring for height and load limitations
(Fig. 153). Replace the spring if out of limits shown
in the figure.
Fig. 152 Oil Pressure Regulator
1 - OIL FILTER
2 - PLUG
3 - GASKET
4 - SPRING
5 - VALVE
Fig. 153 Oil Pressure Regulator Spring Check
BR/BEENGINE 5.9L DIESEL 9 - 297
OIL PAN (Continued)

The turbocharger also uses a wastegate (Fig. 20),
which regulates intake manifold air pressure andprevents over boosting at high engine speeds. When
the wastegate valve is closed, all of the exhaust gases
flow through the turbine wheel. As the intake mani-
fold pressure increases, the wastegate actuator opens
the valve, diverting some of the exhaust gases away
from the turbine wheel. This limits turbine shaft
speed and air output from the impeller.
The turbocharger is lubricated by engine oil that is
pressurized, cooled, and filtered. The oil is delivered
to the turbocharger by a supply line that is tapped
into the oil filter head. The oil travels into the bear-
ing housing, where it lubricates the shaft and bear-
ings (Fig. 21). A return pipe at the bottom of the
Fig. 18 Turbocharger Operation
1 - TURBINE SECTION
2 - EXHAUST GAS
3 - BEARING HOUSING
4 - COMPRESSOR SECTION
5 - INLET AIR
6 - COMPRESSED AIR TO ENGINE
7 - EXHAUST GAS
8 - EXHAUST GAS TO EXHAUST PIPE
Fig. 19 Turbocharger Wastegate Actuator
1 - TURBOCHARGER
2 - DIAPHRAGM
3 - WASTE GATE ACTUATOR
Fig. 20 Wastegate Operation
1 - SIGNAL LINE
2 - EXHAUST BYPASS VALVE
3 - WASTEGATE
4 - EXHAUST
5 - TURBINE
6 - EXHAUST BYPASS VALVE
7 - WASTEGATE
8 - EXHAUST
9 - TURBINE
10 - SIGNAL LINE
11 - 14 EXHAUST SYSTEMBR/BE
TURBOCHARGER (Continued)

CAUTION: The turbocharger is only serviced as an
assembly. Do not attempt to repair the turbocharger
as turbocharger and/or engine damage can result.
CLEANING
Clean the turbocharger and exhaust manifold
mounting surfaces with a suitable scraper.
INSPECTION
Visually inspect the turbocharger and exhaust
manifold gasket surfaces. Replace stripped or eroded
mounting studs.
(1) Visually inspect the turbocharger for cracks.
The following cracks are NOT acceptable:
²Cracks in the turbine and compressor housing
that go completely through.
²Cracks in the mounting flange that are longer
than 15 mm (0.6 in.).
²Cracks in the mounting flange that intersect
bolt through-holes.
²Two (2) Cracks in the mounting flange that are
closer than 6.4 mm (0.25 in.) together.
(2) Visually inspect the impeller and compressor
wheel fins for nicks, cracks, or chips. Note: Some
impellers may have a factory placed paint mark
which, after normal operation, appears to be a crack.Remove this mark with a suitable solvent to verify
that it is not a crack.
(3) Visually inspect the turbocharger compressor
housing for an impeller rubbing condition (Fig. 25).
Replace the turbocharger if the condition exists.
(4) Measure the turbocharger axial end play:
(a) Install a dial indicator as shown in (Fig. 26).
Zero the indicator at one end of travel.
(b) Move the impeller shaft fore and aft and
record the measurement. Allowable end play is
0.038 mm (0.0015 in.) MIN. and 0.089 mm (0.0035
in.) MAX. If the recorded measurement falls out-
side these parameters, replace the turbocharger
assembly.
(5) Measure the turbocharger bearing radial clear-
ance:
(a) Insert a narrow blade or wire style feeler
gauge between the compressor wheel and the hous-
ing (Fig. 27).
(b) Gently push the compresser wheel toward
the housing and record the clearance.
(c) With the feeler gauge in the same location,
gently push the compressor wheel away from the
housing and again record the clearance.
(d) Subtract the smaller clearance from the
larger clearance. This is the radial bearing clear-
ance.
(e) Allowable radial bearing clearance is 0.326
mm (0.0128 in.) MIN. and 0.496 mm (0.0195 in.)
MAX. If the recorded measurement falls outside
these specifications, replace the turbocharger assy.
INSTALLATION
(1) Install the turbocharger. Apply anti-seize to the
studs and then tighten the turbocharger mounting
nuts to 32 N´m (24 ft. lbs.) torque.
(2) Install the oil drain tube and oil supply line to
the turbocharger (Fig. 24). Tighten the drain tube
bolts to 24 N´m (18 ft. lbs.) torque.
Fig. 24 Oil Supply Line and Charge Air Cooler Inlet
Duct
1 - EXHAUST PIPE
2 - TURBOCHARGER
3 - AIR INLET TUBE
4 - COOLER INLET DUCT
Fig. 25 Inspect Compressor Housing for Impeller
Rubbing Condition
11 - 16 EXHAUST SYSTEMBR/BE
TURBOCHARGER (Continued)

FRONT LOWER FASCIA
REMOVAL
(1) Open hood.
(2) Remove fasteners at side fender openings.
(3) Remove lower air dam.(Refer to 13 - FRAMES
& BUMPERS/BUMPERS/FRONT AIR DAM -
REMOVAL)
(4) Disengage clips attaching end of upper fascia to
bumper face bar (Fig. 5).
(5) Disengage clips attaching lower fascia to
bumper face bar.
(6) Separate lower fascia from bumper.
INSTALLATION
(1) Position lower fascia on bumper.
(2) Engage clips attaching lower fascia to bumper
face bar.
(3) Install lower air dam.(Refer to 13 - FRAMES &
BUMPERS/BUMPERS/FRONT AIR DAM - INSTAL-
LATION)
(4) Install fasteners at side fender openings.
FRONT FASCIAÐSPORT
REMOVAL
The fascia can be removed from the vehicle without
removing the bumper.
(1) Disconnect wire connectors from fog lamps.
(2) Remove screws attaching rearward edges of
fascia to outer bumper brackets (Fig. 7).
(3) Remove screws attaching bottom of air deflec-
tor.(4) Lift top of fascia upward to disengage from
retaining clips on front bumper.
(5) Pull fascia from front bumper and separate
from vehicle.
INSTALLATION
(1) Position fascia on front bumper.
(2) Engage fascia with retaining clips on front
bumper.
(3) Install screws attaching bottom of fascia to air
deflector.
(4) Align fascia and wheelhouse liners with outer
bumper brackets and install screws.
(5) Connect harness connectors to fog lamps.
FRONT BUMPER
REMOVAL
(1) Support front bumper on a suitable lifting
device.
(2) Remove bolts attaching front bumper outer
bracket to frame rail (Fig. 6).
(3) Remove nuts and stud plates attaching front
bumper to end of frame rail.
(4) Disengage wire connectors from fog lamps, if
equipped.
(5) Separate front bumper from vehicle.
Fig. 4 Fascia Adjustment Ribs
1 - FRONT UPPER FASCIA
2 - ADJUSTMENT RIBS
3 - FRONT LOWER FASCIA
Fig. 5 Front Bumper Lower Fascia
1 - LOWER FASCIA
2 - RETAINING CLIP
3 - BUMPER
BR/BEFRAME & BUMPERS 13 - 3
FRONT FASCIA (Continued)

INSTALLATION
(1) Support front bumper on a suitable lifting
device.
(2) Position front bumper on vehicle.
(3) Engage fog lamp wire connectors, if equipped.
(4) Install nuts and stud plates attaching front
bumper to end of frame rail. Tighten nuts to 94 N´m
(70 ft. lbs.) torque.
(5) Install bolts attaching front bumper outer
bracket to frame rail. Tighten bolts to 94 N´m (70 ft.
lbs.) torque.
FRONT BUMPERÐSPORT
REMOVAL
(1) Disconnect wire connectors from fog lamps.
(2) Remove screws attaching fascia and outer
bumper brackets to wheelhouse liners.(3) Remove screws and push-in fasteners attaching
bottom of fascia to air deflector.
(4) Support bumper on a suitable lifting device.
(5) Remove nuts attaching bumper to inner
bumper brackets (Fig. 7).
(6) Separate bumper from vehicle.
INSTALLATION
(1) Support bumper on a suitable lifting device.
(2) Position bumper on vehicle.
(3) Install nuts attaching bumper to inner bumper
brackets. Tighten nuts to 94 N´m (70 ft. lbs.) torque.
(4) Install screws and push-in fasteners attaching
bottom of fascia to air deflector.
(5) Align fascia and wheelhouse liners with outer
bumper brackets and install screws. See fascia
adjustment in this section.
(6) Connect wire connectors to fog lamps.
Fig. 6 Front Bumper
1 - U-NUT
2 - FRAME
3 - INNER BUMPER BRACKET
4 - FOGLAMP SIGHT SHIELD
5 - BUMPER
6 - 4±WAY CENTER LOCATOR
7 - BLIND PLASTIC RIVET
8 - UPPER FASCIA9 - LOWER FASCIA
10 - AIR DAM
11 - BLIND PLASTIC RIVET
12 - BLIND PLASTIC RIVET
13 - U-NUT
14 - BLIND RIVET
15 - OUTER BUMPER BRACKET
13 - 4 FRAME & BUMPERSBR/BE
FRONT BUMPER (Continued)

CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Do not drill holes in top
or bottom frame rail flanges, frame rail failure can
result. Do Not use softer than Grade 5 bolts to
replace production fasteners, loosening or failure
can result. When using heat to straighten frame
components do not exceed 566ÉC (1050ÉF), metal
fatigue can result. Welding the joints around riveted
cross members and frame side rails can weaken
frame.
FRAME STRAIGHTENING
When necessary, a conventional frame that is bent
or twisted can be straightened by application of heat.
The temperature must not exceed 566ÉC (1050ÉF).
The metal will have a dull red glow at the desired
temperature. Excessive heat will decrease the
strength of the metal and result in a weakened
frame.
Welding the joints around riveted cross members
and frame side rails is not recommended.
A straightening repair process should be limited to
frame members that are not severely damaged. The
replacement bolts, nuts and rivets that are used to
join the frame members should conform to the same
specifications as the original bolts, nuts and rivets.
FRAME REPAIRS
DRILLING HOLES
Do not drill holes in frame side rail top and bottom
flanges, metal fatigue can result causing frame fail-
ure. Holes drilled in the side of the frame rail must
be at least 38 mm (1.5 in.) from the top and bottom
flanges.
Additional drill holes should be located away from
existing holes.
WELDING
Use MIG, TIG or arc welding equipment to repair
welded frame components.
Frame components that have been damaged should
be inspected for cracks before returning the vehicle
to use. If cracks are found in accessible frame com-
ponents perform the following procedures.
(1) Drill a hole at each end of the crack with a 3
mm (O.125 in.) diameter drill bit.
(2) Using a suitable die grinder with 3 inch cut off
wheel, V-groove the crack to allow 100% weld pene-
tration.
(3) Weld the crack.(4) If necessary when a side rail is repaired, grind
the weld smooth and install a reinforcement channel
(Fig. 9) over the repaired area.
NOTE: If a reinforcement channel is required, the
top and bottom flanges should be 0.250 inches nar-
rower than the side rail flanges. Weld only in the
areas indicated (Fig. 9).
FRAME FASTENERS
Bolts, nuts and rivets can be used to repair frames
or to install a reinforcement section on the frame.
Bolts can be used in place of rivets. When replacing
rivets with bolts, install the next larger size diameter
bolt to assure proper fit. If necessary, ream the hole
out just enough to sufficiently receive the bolt.
Conical-type washers are preferred over the split-
ring type lock washers. Normally, grade-5 bolts are
adequate for frame repair.Grade-3 bolts or softer
should not be used.Tightening bolts/nuts with the
correct torque, refer to the Introduction Group at the
front of this manual for tightening information.
SPECIFICATIONS
FRAME DIMENSION
Frame dimensions are listed in Millimeters (mm)
scale. All dimensions are from center to center of
Principal Locating Point (PLP), or from center to cen-
ter of PLP and fastener location (Fig. 10).
Fig. 9 Frame Reinforcement
1 - .250 IN FROM EDGE
2 - TOP FLANGE
3 - BOTTOM FLANGE
4 - FRAME RAIL
5 - FRAME REPAIR REINFORCEMENT
BR/BEFRAME & BUMPERS 13 - 7
FRAME (Continued)

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)

(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)