fuel type DODGE RAM 2001 Service Owner's Guide

DIAGNOSIS AND TESTINGÐENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL
PRESSURE LOW1. Low oil level. 1. (a) Check and fill with clean engine oil.
(b) Check for a severe external oil leak that
could reduce the pressure.
2. Oil viscosity thin, diluted or wrong
specification.2. Verify the correct engine oil is being
used. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
3. Improperly operating pressure
switch/gauge.3. Verify the pressure switch is functioning
correctly. If not, replace switch/gauge.
4. Relief valve stuck open. 4. Check/replace valve.
5. Plugged oil filter. 5. Change oil filter.
6. If cooler was replaced, shipping
plugs may have been left in cooler6. Check/remove shipping plugs.
7. Worn oil pump. 7. Check and replace oil pump.
8. Suction tube loose or seal leaking. 8. Check and replace seal.
9. Loose main bearing cap. 9. Check and install new bearing. Tighten
cap to proper torque.
10. Worn bearings or wrong bearings
installed.10. Inspect and replace connecting rod or
main bearings. Check and replace piston
cooling nozzles.
11. Oil jet under piston bad fit into
main carrier.11. Check oil jet position.
LUBRICATING OIL
PRESSURE TOO HIGH1. Pressure switch/gauge not
operating properly.1. Verify pressure switch is functioning
correctly. If not, replace switch/gauge.
2. Engine running to cold. 2. Refer to Coolant Temperature Below
Normal (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
3. Oil viscosity too thick. 3. Make sure the correct oil is being used.
(Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
4. Oil pressure relief valve stuck
closed or binding4. Check and replace valve.
LUBRICATING OIL LOSS 1. External leaks. 1. Visually inspect for oil leaks. Repair as
required.
2. Crankcase being overfilled. 2. Verify that the correct dipstick is being
used.
3. Incorrect oil specification or
viscosity.3. (a) Make sure the correct oil is being
used (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(b) Look for reduced viscosity from dilution
with fuel.
(c) Review/reduce oil change intervals.
9 - 232 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)

EXCESSIVE BLACK SMOKE
POSSIBLE CAUSE CORRECTION
Raw fuel in intake manifold. Fuel injectors leaking on engine shutdown. Do Fuel
Injector Test (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR - DIAGNOSIS AND
TESTING).
Static timing not correct. A DTC should have been set. If so, refer to Powertrain
Diagnostic Procedures Information. Also (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION
PUMP - DIAGNOSIS AND TESTING).
Turbocharger air intake restriction. Remove restriction.
Turbocharger damaged. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
Turbocharger has excess build up on compressor
wheel and/or diffuser vanes.(Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - CLEANING).
Turbocharger wheel clearance out of specification. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
EXCESSIVE WHITE SMOKE
POSSIBLE CAUSE CORRECTION
Air in fuel supply: Possible leak in fuel supply side
(between transfer pump and fuel tank module).(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL
TRANSFER PUMP - DIAGNOSIS AND TESTING).
Coolant leaking into combustion chamber. Do pressure test of cooling system (Refer to 7 -
COOLING - DIAGNOSIS AND TESTING).
Diagnostic Trouble Codes (DTC's) active or multiple,
intermittent DTC's.Refer to Powertrain Diagnostic Procedures Information.
In very cold ambient temperatures, engine block heater
is malfunctioning (if equipped).(Refer to 7 - COOLING/ENGINE/ENGINE BLOCK
HEATER - REMOVAL).
Engine coolant temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also check
thermostat operation (Refer to 7 - COOLING/ENGINE/
ENGINE COOLANT THERMOSTAT - DIAGNOSIS AND
TESTING).
Engine Control Module (ECM) not calibrated or has
incorrect calibration.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Fuel filter plugged. Perform Fuel Pressure Drop Test (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL TRANSFER PUMP -
DIAGNOSIS AND TESTING).
Fuel grade not correct or fuel quality is poor. Temporarily change fuel brands and note condition.
Change brand if necessary.
Fuel heater element or fuel heater temperature sensor
malfunctioning. This will cause wax type build-up in fuel
filter.Refer to Fuel Heater Testing (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL HEATER -
DIAGNOSIS AND TESTING).
Fuel injector malfunctioning. A DTC should have been set. Perform9Cylinder
Balance Test9using DRB scan tool to isolate individual
cylinders. Also refer to Powertrain Diagnostic
Procedures Information and, (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
DIAGNOSIS AND TESTING).
Fuel injector hold-downs loose. Torque to specifications.
BR/BEENGINE 5.9L DIESEL 9 - 235
ENGINE 5.9L DIESEL (Continued)

vent corrosion. MopartGasket Sealant is available in
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
STANDARD PROCEDUREÐREPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDUREÐHYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Disconnect the negative cable(s) from the bat-
tery.
(2) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(3) Place a shop towel around the fuel injectors to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the fuel injectors (Refer
to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL
INJECTOR - REMOVAL).
(4) With all injectors removed, rotate the crank-
shaft using a breaker bar and socket.
(5) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(6) Be sure all fluid has been removed from the
cylinders.
(7) Repair engine or components as necessary to
prevent this problem from occurring again.
(8) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(9) Install new fuel injectors (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
(10) Drain engine oil. Remove and discard the oil
filter (Refer to 9 - ENGINE/LUBRICATION/OIL FIL-
TER - REMOVAL).
(11) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(12) Install a new oil filter (Refer to 9 - ENGINE/
LUBRICATION/OIL FILTER - INSTALLATION).
(13) Fill engine crankcase with the specified
amount and grade of oil (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES - SPECIFICA-
TIONS).
(14) Connect the negative cable(s) to the battery.
(15) Start the engine and check for any leaks.
REMOVALÐENGINE
(1) Disconnect both battery negative cables.
(2) Recover A/C refrigerant (if A/C equipped) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE).
(3) Raise vehicle on hoist.
(4) Drain engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(5) Remove engine oil drain plug and drain engine
oil.
(6) Lower vehicle.
(7) Remove radiator upper hose.
(8) Remove the cooling fan shroud-to-radiator
mounting bolts.
9 - 238 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)

(23) Connect the transmission quick-connect oil
cooler lines to the radiator. Push together until an
audible ªclickº is heard. Verify connection by pulling
apart.
(24) Raise vehicle.
(25) Connect a/c compressor suction/discharge hose
(if a/c equipped).
(26) Install the radiator lower hose and clamps.
(27) Install the starter motor (Refer to 8 - ELEC-
TRICAL/STARTING/STARTER MOTOR - INSTAL-
LATION).
(28) Install the transmission and transfer case (if
equipped).
(29) Connect the exhaust pipe to the turbocharger
elbow (Fig. 3). Torque the bolts to 34 N´m (25 ft. lbs.)
torque.
(30) Connect the transmission auxiliary oil cooler
lines (if equipped).
(31) Lower the vehicle
(32) Connect the heater core supply and return
hoses.
(33) Install the cooling fan and shroud at the same
time (Refer to 7 - COOLING/ENGINE/RADIATOR
FAN - INSTALLATION).
(34) Install the coolant recovery bottle to the fan
shroud (Fig. 2) and connect the hose to the radiator
filler neck.
(35) Install the windshield washer bottle to the fan
shroud and connect the pump supply hose and elec-
trical connections.
(36) Install the radiator upper hose and clamps.
(37) Change oil filter and install new engine oil.
(38) Fill cooling system with coolant (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(39) Connect battery negative cables.
(40) Perform the fuel line air bleed procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(41) Start engine and inspect for engine oil, cool-
ant, and fuel leaks.
INSTALLATIONÐCRANKCASE BREATHER
VAPOR CANISTER
(1) Position vapor canister with strap over stud on
engine front cover. Install retaining nut. Tighten nut
10 N´m ( 89 in. lbs.).
(2) If removed, position hose onto crankcase
breather, then position clamp.
(3) Position lower portion of hose into vapor canis-
ter, then install and tighten cap.
SPECIFICATIONS
5.9L DIESEL
DESCRIPTION SPECIFICATION
Engine Type In-Line 6 Cyl. Turbo
Diesel
Bore and Stroke 102.0 X 120.0 mm
(4.02 X 4.72 in.)
Displacement 5.9L (359 cu. in.)
Compression Ratio
245 H.P. Version 17.0:1
235 H.P. Version 16.3:1
Horsepower (A/T and 5
Speed M/T)235 @ 2700 rpm
Horsepower (6 Speed M/T
Only)245 @ 2700 rpm
Torque Rating (A/T and 5
Speed M/T)460 ft. lbs. @ 1600 rpm
Torque Rating (6 Speed
M/T Only)505 ft. lbs. @ 1600 rpm
Firing Order 1-5-3-6-2-4
Lubrication System Pressure Feed-Full Flow
With Bypass Valve
Cylinder Block Cast Iron
Crankshaft Induction Hardened
Forged Steel
Cylinder Head Cast Iron With Valve
Seat Inserts
Combustion Chambers High Swirl Bowl
Camshaft Chilled Ductile Iron
Pistons Cast Aluminum
Connecting Rods Cross Rolled Micro Alloy
PISTONS AND CONNECTING RODS
Piston
Skirt Diameter 101.864 ± 101.88 mm
(4.0104 ± 4.011 in.)
Ring Groove Clearance
Intermediate (Max.) 0.095 mm (0.0037 in.)
Oil Control (Max.) 0.085 mm (0.0033 in.)
Piston Pins
Pin Diameter (Min.) 39.990 mm (1.5744 in.)
Bore Diameter (Max.) 40.025 mm (1.5758 in.)
Piston Ring End Gap
Top Ring 0.35 ± 0.45 mm
9 - 242 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)

FRAME
DESCRIPTION
The BR/BE frame is the structural center of the
vehicle. In addition to supporting the body and pay-
load, the frame provides a station for the engine and
drivetrain. BR/BE trucks have a ladder type frame
with Box-section front rails, dropped center section,
and open-channel side rails in the rear.
Cross members attach to the side rails with rivets,
welds, or bolts. The cab is isolated from the frame
with rubber load cushions with through bolts. The
cargo box or bed is attached to the frame with bolts.
The frame is designed to absorb and dissipate flex-
ing and twisting due to acceleration, braking, corner-
ing, and road surface variances without bending
when subjected to normal driving conditions.
FRAME SERVICE
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT. BEFORE PROCEEDING WITH FRAME
REPAIR INVOLVING GRINDING OR WELDING, VER-
IFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING
OR IN CONTACT WITH REPAIR AREA, PERSONAL
INJURY CAN RESULT. DO NOT ALLOW OPEN
FLAME TO CONTACT PLASTIC BODY PANELS.
FIRE OR EXPLOSION CAN RESULT. WHEN
WELDED FRAME COMPONENTS ARE REPLACED,
100% PENETRATION WELD MUST BE ACHIEVED
DURING INSTALLATION. IF NOT, DANGEROUS
OPERATING CONDITIONS CAN RESULT. STAND
CLEAR OF CABLES OR CHAINS ON PULLING
EQUIPMENT DURING FRAME STRAIGHTENING
OPERATIONS, PERSONAL INJURY CAN RESULT.
DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT SUPPORTED ON SAFETY STANDS,
PERSONAL INJURY CAN RESULT.
Fig. 8 Rear Bumper
1 - INNER BRACKET
2 - BUMPER3 - OUTER BRACKET
13 - 6 FRAME & BUMPERSBR/BE
REAR BUMPER (Continued)

Refer to Fuel System Pressure Release in Fuel
Delivery System section of this group.
The fuel filter/fuel pressure regulator (Fig. 3) is
located at top of fuel pump module (Fig. 4) or (Fig. 5).
Fuel pump module removal is not necessary.
(1) Drain fuel tank and remove tank. Refer to Fuel
Tank Removal/Installation.
(2) The fuel filter/regulator is pressed into a rub-
ber grommet. Remove by twisting and pulling
straight up (Fig. 6).
CAUTION: Do not pull filter/regulator more than
three inches from fuel pump module. Damage to
coiled fuel tube (line) may result.
(3) Gently cut old fuel tube (line) clamp (Fig. 7)
taking care not to damage plastic fuel tube. Remove
and discard old fuel tube clamp.
(4) Remove plastic fuel tube from filter/regulator
by gently pulling downward. Remove filter/regulator
from fuel pump module.
INSTALLATION
(1) Install a new clamp over plastic fuel tube.
(2) Install filter/regulator to fuel tube. Rotate fil-
ter/regulator in fuel tube (line) (Fig. 8) until it is
pointed to drivers side of vehicle (Fig. 4) or (Fig. 5).
(3) Tighten line clamp to fuel line using special
Hose Clamp Pliers number C-4124 or equivalent
(Fig. 8).Do not use conventional side cutters to
tighten this type of clamp.
Fig. 3 Fuel Filter/Fuel Pressure Regulator
1 - INTERNAL FUEL FILTER
2 - FUEL FLOW TO FUEL INJECTORS
3 - FUEL FILTER/FUEL PRESSURE REGULATOR
4 - EXCESS FUEL BACK TO TANK
5 - FUEL INLET
6 - RUBBER GROMMET
7 - TOP OF PUMP MODULE
Fig. 4 Filter/Regulator LocationÐWith 26 or 34
Gallon Fuel 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. 5 Filter/Regulator LocationÐWith 35 Gallon
Fuel Tank
1 - FUEL FILTER/PRESSURE REGULATOR
2 - FUEL SUPPLY FITTING
3 - ELECTRICAL CONNECTOR
4 - LOCKNUT
5 - FUEL PUMP MODULE
6 - AUXILIARY CAPPED FITTING
14 - 6 FUEL DELIVERY - GASOLINEBR/BE
FUEL FILTER/PRESSURE REGULATOR (Continued)

INSTALLATION
The fuel gauge sending unit (fuel level sensor) and
float assembly is located on the side of fuel pump
module (Fig. 9). The fuel pump module is located
inside of fuel tank.
(1) Position sending unit into tracks. Note wire
routing.
(2) Push unit on tracks until lock tab snaps into
notch.
(3) Connect 2 sending unit wires into 4±way con-
nector and install locking collar.
(4) Connect 4±way electrical connector to module.
(5) Install fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(6) Install fuel tank. Refer to Fuel Tank±All
Engines in the Removal/Installation section.
FUEL LINES
DESCRIPTION
Also refer to Quick-Connect Fittings.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES, FIT-
TINGS OR LINES, THE FUEL SYSTEM PRESSURE
MUST BE RELEASED. REFER TO THE FUEL SYSTEM
PRESSURE RELEASE PROCEDURE IN THIS GROUP.
The lines/tubes/hoses used on fuel injected vehicles
are of a special construction. This is due to the
higher fuel pressures and the possibility of contami-
nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, only those marked EFM/EFI
may be used.
If equipped:The hose clamps used to secure rub-
ber hoses on fuel injected vehicles are of a special
rolled edge construction. This construction is used to
prevent the edge of the clamp from cutting into the
hose. Only these rolled edge type clamps may be
used in this system. All other types of clamps may
cut into the hoses and cause high-pressure fuel leaks.
Use new original equipment type hose clamps.
FUEL PUMP
DESCRIPTION
The fuel pump is located inside of the fuel pump
module. A 12 volt, permanent magnet, electric motor
powers the fuel pump.
OPERATION
Voltage to operate the electric pump is supplied
through the fuel pump relay.Fuel is drawn in through a filter at the bottom of
the module and pushed through the electric motor
gearset to the pump outlet.
Check Valve Operation:The pump outlet con-
tains a one-way check valve to prevent fuel flow back
into the tank and to maintain fuel supply line pres-
sure (engine warm) when pump is not operational. It
is also used to keep the fuel supply line full of gaso-
line when pump is not operational. After the vehicle
has cooled down, fuel pressure may drop to 0 psi
(cold fluid contracts), but liquid gasoline will remain
in fuel supply line between the check valve and fuel
injectors.Fuel pressure that has dropped to 0
psi on a cooled down vehicle (engine off) is a
normal condition.Refer to the Fuel Pressure Leak
Down Test for more information.
DIAGNOSIS AND TESTING - FUEL PUMP
CAPACITY TEST
Before performing this test, verify fuel pump
pressure. Refer to Fuel Pump Pressure Test.
Use this test in conjunction with the Fuel Pres-
sure Leak Down Test.
(1) Release fuel system pressure. Refer to Fuel
Pressure Release Procedure.
(2) Disconnect fuel supply line at fuel rail. Refer to
Quick-Connect Fittings. Some engines may require
air cleaner housing removal before line disconnection.
(3) Obtain correct Fuel Line Pressure Test Adapter
Tool Hose. Tool number 6539 is used for 5/16º fuel
lines and tool number 6631 is used for 3/8º fuel lines.
(4)
Connect correct Fuel Line Pressure Test Adapter
Tool Hose into disconnected fuel supply line. Insert other
end of Adaptor Tool Hose into a graduated container.
(5) Remove fuel fill cap.
(6) To activate fuel pump and pressurize system,
obtain DRBtscan tool and actuate ASD Fuel System
Test.
(7) A good fuel pump will deliver at least 1/4 liter
of fuel in 7 seconds. Do not operate fuel pump for
longer than 7 seconds with fuel line disconnected as
fuel pump module reservoir may run empty.
(a) If capacity is lower than specification, but
fuel pump can be heard operating through fuel fill
cap opening, check for a kinked/damaged fuel sup-
ply line somewhere between fuel rail and fuel
pump module.
(b) If line is not kinked/damaged, and fuel pres-
sure is OK, but capacity is low, replace fuel filter/
fuel pressure regulator. The filter/regulator may be
serviced separately on certain applications. Refer
to Fuel Filter/Fuel Pressure Regulator Removal/In-
stallation for additional information.
(c) If both fuel pressure and capacity are low,
replace fuel pump module assembly. Refer to Fuel
Pump Module Removal/Installation.
BR/BEFUEL DELIVERY - GASOLINE 14 - 9
FUEL LEVEL SENDING UNIT / SENSOR (Continued)

(1) Be sure fuel tank contains fuel before starting
test. If tank is empty or near empty, amperage read-
ings will be incorrect.
(2) Obtain LCS adapter.
(3) Plug cable from LCS adapter into DRB scan
tool at SET 1 receptacle.
(4) Plug DRB into vehicle 16±way connector (data
link connector).
(5) Connect (-) and (+) test cable leads into LCS
adapter receptacles. Use10 amp (10A +)receptacle
and common (-) receptacles.
(6) Gain access to MAIN MENU on DRB screen.
(7) Press DVOM button on DRB.
(8) Using left/right arrow keys, highlight CHAN-
NEL 1 function on DRB screen.
(9) Press ENTER three times.
(10) Using up/down arrow keys, highlight RANGE
on DRB screen (screen will default to 2 amp scale).
(11) Press ENTER to change 2 amp scale to 10
amp scale.This step must be done to prevent
damage to DRB scan tool or LCS adapter
(blown fuse).
(12) Remove cover from Power Distribution Center
(PDC).
(13) Remove fuel pump relay from PDC. Refer to
label on PDC cover for relay location.
WARNING: BEFORE PROCEEDING TO NEXT STEP,
NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI-
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND
FUEL SYSTEM COMPONENTS ARE CONNECTED.
CAUTION: To prevent possible damage to the vehi-
cle electrical system and LCS adapter, the test
leads must be connected into relay cavities exactly
as shown in following steps.
Depending upon vehicle model, year or engine con-
figuration, three different types of relays may be
used: Type-1, type-2 and type±3.
(14) If equipped withtype±1 relay(Fig. 13),
attach test leads from LCS adapter into PDC relay
cavities number 30 and 87. For location of these cav-
ities, refer to numbers stamped to bottom of relay
(Fig. 13).
(15) If equipped withtype±2 relay(Fig. 14),
attach test leads from LCS adapter into PDC relay
cavities number 30 and 87. For location of these cav-
ities, refer to numbers stamped to bottom of relay
(Fig. 14).(16) If equipped withtype±3 relay(Fig. 15),
attach test leads from LCS adapter into PDC relay
cavities number 3 and 5. For location of these cavi-
ties, refer to numbers stamped to bottom of relay
(Fig. 15).
Fig. 13 FUEL PUMP RELAY - TYPE 1
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 14 FUEL PUMP RELAY - TYPE 2
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
BR/BEFUEL DELIVERY - GASOLINE 14 - 11
FUEL PUMP (Continued)

(17) When LCS adapter test leads are attached
into relay cavities, fuel pumpwill be activated.
Determine fuel pump amperage on DRB screen.
Amperage should be below 10.0 amps. If amperage is
below 10.0 amps, and specifications for the Fuel
Pump Pressure, Fuel Pump Capacity and Fuel Pres-
sure Leak Down tests were met, the fuel pump mod-
ule is OK.
(18) If amperage is more than 10.0 amps, replace
fuel pump module assembly. The electric fuel pump
is not serviced separately.
(19) Disconnect test leads from relay cavities
immediately after testing.
FUEL PUMP MODULE
DESCRIPTION
The fuel pump module on all gas powered engines
is installed in the top of the fuel tank (Fig. 16) or
(Fig. 17). The fuel pump module (Fig. 16), (Fig. 17)or
(Fig. 18)contains the following:
²A combination fuel filter/fuel pressure regulator
²Electric fuel pump
²Fuel pump reservoir
²A separate in-tank fuel filter (at bottom of mod-
ule)²Rollover valve (certain modules)
²Fuel gauge sending unit (fuel level sensor)
²Fuel supply line connection at filter/regulator
²A threaded locknut retaining pump module to
fuel tank
²A gasket between tank flange and module
²Auxiliary non-pressurized fuel supply fitting (not
all engines)
The fuel gauge sending unit (fuel level sensor), and
pick-up filter (at bottom of module) may be serviced
separately. If the electrical fuel pump requires ser-
vice, the entire fuel pump module must be replaced.
The fuel filter/fuel pressure regulator may be ser-
viced separately. Refer to Fuel Filter/Fuel Pressure
Regulator Removal/Installation for additional infor-
mation.
Fig. 15 FUEL PUMP RELAY - TYPE 3
TERMINAL LEGEND
NUMBER IDENTIFICATION
1 COIL BATTERY
2 COIL GROUND
3 COMMON FEED
4 NORMALLY CLOSED
5 NORMALLY OPEN
Fig. 16 Fuel Pump Module - Gas Powered With 26
or 34 Gallon Tank±Typical
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
14 - 12 FUEL DELIVERY - GASOLINEBR/BE
FUEL PUMP (Continued)

(7) Connect two mounting straps and mounting
strap nuts.
(8) Tighten strap nuts to 41 N´m (30 ft. lbs.)
torque. Do not over tighten retaining strap nuts.
(9) Remove transmission jack.
(10) Connect fuel filler tube assembly to body.
(11) If equipped, connect grounding wire (strap)
and screw.
(12) Refill fuel tank and inspect all hoses and lines
for leaks.
(13)
Connect negative battery cable(s) to battery(s).
INLET FILTER
REMOVAL
The fuel pump inlet filter (strainer) is located on
the bottom of the fuel pump module (Fig. 40). The
fuel pump module is located inside of fuel tank.
(1) Remove fuel tank. Refer to Fuel Tank Removal/
Installation.
(2) Remove fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(3) Remove filter by carefully prying 2 lock tabs at
bottom of module with 2 screwdrivers. Filter is
snapped to module.
(4) Clean bottom of pump module.
INSTALLATION
The fuel pump inlet filter (strainer) is located on
the bottom of the fuel pump module (Fig. 40). The
fuel pump module is located inside of fuel tank.
(1) Snap new filter to bottom of module. Be sure
o-ring is in correct position.(2) Install fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(3) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
QUICK CONNECT FITTING
DESCRIPTION
Different types of quick-connect fittings are used to
attach various fuel system components, lines and
tubes. These are: a single-tab type, a two-tab type or
a plastic retainer ring type. Some are equipped with
safety latch clips. Some may require the use of a spe-
cial tool for disconnection and removal. Refer to
Quick-Connect Fittings Removal/Installation for more
information.
CAUTION: The interior components (o-rings, clips)
of quick-connect fittings are not serviced sepa-
rately, but new plastic spacers are available for
some types. If service parts are not available, do
not attempt to repair the damaged fitting or fuel line
(tube). If repair is necessary, replace the complete
fuel line (tube) assembly.
STANDARD PROCEDURES - QUICK-CONNECT
FITTINGS
Also refer to Fuel Tubes/Lines/Hoses and Clamps.
Different types of quick-connect fittings are used to
attach various fuel system components, lines and
tubes. These are: a single-tab type, a two-tab type or
a plastic retainer ring type. Safety latch clips are
used on certain components/lines. Certain fittings
may require use of a special tool for disconnection.
DISCONNECTING
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSE,
FITTING OR LINE, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
CAUTION: The interior components (o-rings, spac-
ers) of some types of quick-connect fitting are not
serviced separately. If service parts are not avail-
able, do not attempt to repair a damaged fitting or
fuel line. If repair is necessary, replace complete
fuel line assembly.
(1) Perform fuel pressure release procedure. Refer
to Fuel Pressure Release Procedure.
(2) Disconnect negative battery cable from battery.
Fig. 40 Fuel Pump Inlet Filter
1 - FUEL PUMP INLET FILTER
2 - LOCK TABS (2)
3 - FUEL PUMP MODULE (BOTTOM)
14 - 22 FUEL DELIVERY - GASOLINEBR/BE
FUEL TANK (Continued)