heater DODGE RAM 2003 Service Repair Manual

heater. The heater can be check at room tempera-
ture. Operating range is 0.3 Ð 0.45 Ohms.
(3) Replace heater if resistance is not within oper-
ating range.
(4) If heater is within operating range, replace
heater thermostat.
REMOVAL
REMOVAL/INSTALLATION
The fuel heater/element/sensor assembly is located
inside of the fuel filter housing. Refer to Fuel Filter/
Water Separator Removal/Installation for procedures.
FUEL HEATER RELAY
DESCRIPTION
The fuel heater relay is located in Power Distribu-
tion Center (PDC) (Fig. 6). Refer to label on inside of
PDC cover for relay location.
OPERATION
Battery voltage to operate the fuel heater element
is supplied from the ignition switch through the fuel
heater relay.The fuel heater element and fuel
heater relay are not computer controlled.
REMOVAL
The fuel heater relay is located in the Power Dis-
tribution Center (PDC) (Fig. 7). Refer to label under
PDC cover for relay location.
(1) Remove PDC cover.
(2) Remove relay from PDC.(3) Check condition of relay terminals and PDC
connector terminals for damage or corrosion. Repair
if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
INSTALLATION
The fuel heater relay is located in the Power Dis-
tribution Center (PDC) (Fig. 7). Refer to label under
PDC cover for relay location.
(1) Install relay to PDC.
(2) Install cover to PDC.
FUEL INJECTION PUMP
DESCRIPTION
A Robert Bosch high-pressure fuel injection pump
is used. The pump is attached to the back of the tim-
ing gear cover at the left / rear side of the engine.
OPERATION
The fuel injection pump supplies high pressure to
the fuel rail independent of engine speed. This high
pressure is then accumulated in the fuel rail. High
pressure fuel is constantly supplied to the injectors
by the fuel rail. The Engine Control Module (ECM)
controls the fueling and timing of the engine by actu-
ating the injectors.
Fuel enters the system from the electric fuel trans-
fer (lift) pump, which is attached to the fuel filter
assembly. Fuel is forced through the fuel filter ele-
ment and then enters the Fuel Pump/Gear Pump,
which is attached to the rear of the fuel injection
Fig. 6 POWER DISTRIBUTION CENTER LOCATION
1 - CLIP
2 - BATTERY
3 - TRAY
4 - NEGATIVE CABLE
5 - POSITIVE CABLE
6 - CLIP
7 - FENDER INNER SHIELD
8 - POWER DISTRIBUTION CENTER
Fig. 7 POWER DISTRIBUTION CENTER LOCATION
1 - CLIP
2 - BATTERY
3 - TRAY
4 - NEGATIVE CABLE
5 - POSITIVE CABLE
6 - CLIP
7 - FENDER INNER SHIELD
8 - POWER DISTRIBUTION CENTER
14 - 64 FUEL DELIVERY - DIESELDR
FUEL HEATER (Continued)

pump. The Fuel Pump/Gear Pump is a low-pressure
pump and produce pressures ranging from 551.5 kpa
(80 psi) to 1241 kpa (180) psi. Fuel then enters the
fuel injection pump. Low pressure fuel is then sup-
plied to the FAC (Fuel Control Actuator).
The FAC is an electronically controlled solenoid
valve. The ECM controls the amount of fuel that
enters the high-pressure pumping chambers by open-
ing and closing the FAC based on a demanded fuel
pressure. The FPS (Fuel Pressure Sensor) on the fuel
rail provides the actual fuel pressure. When the
actuator is opened, the maximum amount of fuel is
being supplied to the fuel injection pump. Any fuel
that does not enter the injection pump is directed to
the overflow valve. The overflow valve regulates how
much excess fuel is used for lubrication of the pump
and how much is returned to the tank through the
drain manifold.
Fuel entering the injection pump is pressurized to
between 300 - 1600 bar by three radial pumping
chambers. The pressurized fuel is then supplied to
the fuel rail.
DIAGNOSIS AND TESTING - FUEL INJECTION
PUMP TIMING
With the Bosch injection pump, there are no
mechanical adjustments needed or necessary to
accomplish fuel injection timing. All timing and fuel
adjustments are electrically made by the engine
mounted Engine Control Module (ECM).
REMOVAL
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and pos-
sible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Disconnect both negative battery cables at both
batteries. Cover and isolate ends of both cables.
(2) Remove intake manifold air intake tube (above
injection pump) and its rubber connector hose (Fig.
8).
(3) The Engine Control Module (ECM) is mounted
to left side of engine (Fig. 9). Remove 5 ECM mount-ing bolts and position ECM for injection pump
removal.Do not disconnect wiring connectors
from ECM.
(4) Remove cooling fan shroud.
(5) Remove cooling fan assembly.
(6) Remove accessory drive belt.
(7) Thoroughly clean the rear of injection pump,
and attachment points for its 3 fuel lines (Fig. 10).
Also clean the opposite ends of these same 3 lines at
their attachment points.
(8) Disconnect Fuel Control Actuator (FCA) electri-
cal connector at rear of injection pump (Fig. 11).
(9) Remove fuel line (injection pump-to-overflow
valve).
(10) Remove fuel line (injection pump-to-fuel rail).
(11) Remove fuel line (injection pump-to-fuel filter
housing).
(12) Remove fuel pump drive gear access cover
(plate) with a 1/2 inch drive ratchet. Plate is
threaded to timing gear cover (Fig. 12).
(13) Remove fuel pump drive gear mounting nut
and washer.
(14) Attach C3428B, or L4407A (or equivalent)
gear puller (Fig. 13) to pump drive gear with 2 bolts,
and separate gear from pump (a keyway is not used
on this particular injection pump). Leave drive gear
hanging loose within timing gear cover.
(15) Remove 3 injection pump mounting nuts (Fig.
14), and remove pump from engine.
Fig. 8 INTAKE TUBE AND CONNECTING HOSE
1 - MANIFOLD ABOVE HEATERS
2 - RUBBER CONNECTING HOSE
3 - METAL INTAKE TUBE
4 - CLAMPS (2)
DRFUEL DELIVERY - DIESEL 14 - 65
FUEL INJECTION PUMP (Continued)

(1) Disconnect both negative battery cables from
both batteries. Cover and isolate ends of cables.
(2) Thoroughly clean fuel lines at both the cylinder
head and injection pump ends.
(3) If removing fuel line at either #1 or #2 cylinder,
the intake manifold air heater elements must first be
removed from top of intake manifold. Refer to Intake
Air Heater Removal / Installation for procedures.
(4) If removing fuel line at #6 cylinder, a bracket
(Fig. 16) is located above fuel line connection at cyl-
inder head. Two bolts secure this bracket to rear of
cylinder head. The upper bolt hole is slotted. Loosen
(but do not remove) these 2 bracket bolts. Tilt
bracket down to gain access to #6 fuel line connec-
tion.
(5) Remove necessary insulated fuel line support
clamps (Fig. 17) and bracket bolts at intake manifold.
(6) Place shop towels around fuel lines at fuel rail
and injectors. If possible, do not allow fuel to drip
down side of engine.
CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE LINES ATTACHED TO A SEPA-
RATE FITTING (Fig. 18) , USE A BACK-UP WRENCH
ON FITTING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.(7) Carefully remove each fuel line from engine.
Note position of each while removing.Do not bend
lines while removing.
Fig. 15 TYPICAL TEST FOR LEAKS USING
CARDBOARD
1 - HIGH-PRESSURE LINE
2 - CARDBOARD
3 - TYPICAL HIGH-PRESSURE FITTINGFig. 16 BRACKET - #6 INJECTOR
1 - BRACKET
2 - REAR OF CYLINDER HEAD
3 - FUEL DRAIN MANIFOLD LINE (TO FUEL TANK)
4 - BANJO BOLT
5 - SLOTTED HOLE
6 - BRACKET BOLTS (2)
Fig. 17 FUEL INJECTOR RAIL
1 - FUEL RAIL MOUNTING BOLTS (3)
2 - INSULATED CLAMPS
3 - FUEL INJECTOR RAIL
14 - 70 FUEL DELIVERY - DIESELDR
FUEL LINES (Continued)

INSTALLATION
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.
(1) Position fuel line support clamp to fuel line.
Install clamp nuts/bolts and tighten finger tight.
(2) Position proper fuel line to proper injector on
engine. Tighten fittings hand tight at both ends of
line.
(3) Tighten fuel lines at high pressure injector con-
nector to 30 N´m (22 lb. ft.).
(4) Tighten fuel lines at fuel rail to 30 N´m (22 lb.
ft.).
(5) Tighten clamp/support nuts and bolts.
(6) Install engine lifting bracket and bolt. Tighten
bolt to 77 N´m (56 lb.ft.).(7) If fuel line at either #1 or #2 cylinder has been
replaced, install intake manifold air heater elements
to top of intake manifold. Refer to Intake Air Heater
Removal / Installation for procedures.
(8) If fuel line at #6 cylinder has been replaced, tilt
metal bracket upward and tighten 2 bolts at rear of
cylinder head.
(9) Install remaining fuel line support clamps and
bracket bolts at intake manifold.
(10) Connect both negative battery cables to both
batteries.
(11) Prime fuel system. Refer to Fuel System
Priming.
(12) Check lines/fittings for leaks.
Fig. 18 HIGH PRESSURE FUEL LINES
1 - FUEL INJECTOR
2 - HIGH-PRESSURE LINE
3 - INJECTOR MOUNTING BOLTS
4 - FUEL INJECTOR RAIL5 - SEPARATE FITTING (TYPICAL)
6 - CONNECTOR TUBE RETAINER (FITTING)
7 - CONNECTOR TUBE
DRFUEL DELIVERY - DIESEL 14 - 71
FUEL LINES (Continued)

FUEL PRESSURE SENSOR
DESCRIPTION
The fuel pressure sensor is mounted vertically near
the top/center of the fuel rail.
OPERATION
The fuel pressure sensor monitors actual high-
pressure within the fuel rail. An output signal from
this sensor (relating to fuel pressure) is sent to the
Engine Control Module (ECM).
REMOVAL
The fuel pressure sensor is mounted vertically near
the top/center of the fuel rail (Fig. 19).
(1) Disconnect electrical connector at sensor.
(2) Remove sensor from fuel rail.
(3) Inspect sensor o-ring.
INSTALLATION
(1) Inspect fuel pressure sensor o-ring.
(2) Lubricate sensor o-ring with clean diesel fuel.
(3) Install sensor into fuel rail.
(4) To prevent leaks, sensormustbe tightened to
prescribed torque. Tighten sensor to 101 N´m (75 ft.
lbs.) torque.
(5) Connect electrical connector to sensor.
(6) Start engine and check for fuel leaks.
FUEL PRESSURE LIMITING
VA LV E
DESCRIPTION
The fuel pressure limiting valve is located on the
top of the fuel rail.
OPERATION
Fuel pressure at the fuel rail is monitered by the
fuel rail pressure sensor. If fuel pressure becomes
excessive, the pressure limiting valve opens and
vents excess pressure into the fuel drain circuit.
REMOVAL
The fuel pressure limiting valve is located on the
top of the fuel rail (Fig. 20).
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and pos-
sible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Thoroughly clean area at pressure limiting
valve.
(2) Remove banjo bolt (Fig. 20) at banjo fitting.
(3) Remove pressure limiting valve from intake
manifold.
Fig. 19 FUEL PRESSURE SENSOR/FUEL PRES.
LIMIT. VALVE
1 - ELEC. CONNECTOR
2 - BANJO BOLT
3 - FUEL PRESSURE LIMITING VALVE
4 - FUEL PRESSURE SENSOR
5 - TOP OF INTAKE HEATER MANIFOLD
14 - 72 FUEL DELIVERY - DIESELDR

INSTALLATION
(1) Be sure both top of manifold and limiting valve
are clean.
(2) Assemble banjo bolt and new sealing washers
to limiting valve.
(3) Tighten banjo bolt to 24 N´M (17 ft. lbs.)
torque.
FUEL TANK
DESCRIPTION - DIESEL
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.
REMOVAL - DIESEL
Fuel Tank Draining
Due to a one-way check valve installed into the
fuel fill opening fitting at the tank, the tank cannot
be drained conventionally at the fill cap.
(1) Raise vehicle.(2) If vehicle is equipped with 4 doors and a 6 foot
(short) box, remove left-rear tire/wheel.
(3) Thoroughly clean area at top of fuel tank
around fuel tank module.
(4) Remove rubber cap from auxiliary fitting on
top of tank module (Fig. 21).
(5) Drain fuel tank by attaching drain hose from
an approved draining station to auxiliary fitting on
top of tank module (Fig. 21).
Tank Removal
(1) Loosen clamp and disconnect rubber fuel fill
hose at tank.
(2) Support tank with a hydraulic jack.
(3) Remove 2 fuel tank strap nuts (Fig. 22) and
remove both tank support straps.
(4) Carefully lower tank a few inches and discon-
nect fuel pump module electrical connector (Fig. 21)
at top of tank. To disconnect electrical connector:
Push upward on red colored tab to unlock. Push on
black colored tab while removing connector.
(5) Disconnect fuel supply and return lines at fuel
tank module (Fig. 21). Refer to Quick-Connect Fit-
tings for procedures.
(6) Continue to lower tank for removal.
Fig. 20 FUEL PRESSURE SENSOR/FUEL
PRESSURE LIMITING VALVE
1 - ELEC. CONNECTOR
2 - BANJO BOLT
3 - FUEL PRESSURE LIMITING VALVE
4 - FUEL PRESSURE SENSOR
5 - TOP OF INTAKE HEATER MANIFOLD
Fig. 21 FUEL TANK MODULE - DIESEL
1 - TOP OF FUEL TANK
2 - AUX. FITTING
3 - ELEC. CONNECTOR
4 - FUEL TANK MODULE (TOP)
5 - LOCKNUT
6 - FUEL SUPPLY LINE
7 - FUEL RETURN LINE
DRFUEL DELIVERY - DIESEL 14 - 73
FUEL PRESSURE LIMITING VALVE (Continued)

(4) Be sure pump is positioned flat to fuel filter
housing. Install mounting bolts and evenly tighten to
7 N´m (61 in. lbs.).
(5) Connect fuel line extension at fuel supply line.
(6) Connect electrical connector to pump.
(7)Prime System:Cycle key to actuate transfer
pump or use DRB II Scan Tool to actuate transfer
pump. Check for leaks.
(8) Operate engine and check for fuel leaks.
CASCADE OVERFLOW VALVE
DESCRIPTION
The cascade overflow valve is located on the top/
rear side of the fuel injection pump (Fig. 27).
OPERATION
When the fuel control actuator (FCA) is opened,
the maximum amount of fuel is being delivered to
the fuel injection pump. Any fuel that does not enter
the injection pump is directed to the cascade overflow
valve. The cascade valve regulates how much excess
fuel is used for lubrication of the injection pump, and
is also used to route excess fuel through the drain
circuit and back into the fuel tank.
REMOVAL
REMOVAL/INSTALLATION
The cascade overflow valve is not serviced sepa-
rately.
WATER IN FUEL SENSOR
DESCRIPTION
The Water-In-Fuel (WIF) sensor is located on the
side of the fuel filter/water separator canister (Fig.
28), or (Fig. 29).
Fig. 27 OVERFLOW VALVE
1 - BANJO BOLTS
2 - PUMP MOUNTING NUTS (3)
3 - FUEL INJECTION PUMP
4 - CASCADE OVERFLOW VALVE
Fig. 28 FILTER HOUSING (EARLY)
1 - FILTER HOUSING
2 - FUEL HEATER AND THERMOSTAT
3 - FUEL HEATER MOUNTING SCREWS
4 - FUEL HEATER ELEC. CONNECTOR
5 - DRAIN VALVE
6 - DRAIN VALVE MOUNTING SCREWS
7 - DRAIN HOSE
8 - WIF SENSOR
9 - WIF SENSOR ELEC. CONNECTOR
DRFUEL DELIVERY - DIESEL 14 - 77
FUEL TRANSFER PUMP (Continued)

OPERATION
The sensor sends an input to the Engine Control
Module (ECM) when it senses water in the fuel filter/
water separator. As the water level in the filter/sep-
arator increases, the resistance across the WIF
sensor decreases. This decrease in resistance is sent
as a signal to the ECM and compared to a high
water standard value. Once the value reaches 30 to
40 kilohms, the ECM will activate the water-in-fuel
warning lamp through CCD bus circuits. This all
takes place when the ignition key is initially put in
the ON position. The ECM continues to monitor the
input at the end of the intake manifold air heater
post-heat cycle.
REMOVAL
The Water-In-Fuel (WIF) sensor is located at the
side of fuel filter/water separator canister. Refer to
Fuel Filter/Water Separator Removal/Installation for
WIF sensor removal/installation procedures.
FUEL DRAIN CIRCUIT
OPERATION
The Fuel Drain Circuit incorporates several
sources of fuel return. Fuel travels from the fuel tank
to the fuel transfer pump and is forced through the
fuel filter. A portion of that fuel travels through the
fuel filter and into the fuel injection pump, while the
rest of the fuel flows through a passage in the fuel
filter housing. It then goes to a fuel drain line and
returns back to the fuel tank.
The fuel that flows to the fuel pump is pressurized
and sent into a passage in the fuel pump. At this
point the fuel is channeled into two passages. One
passage sends fuel to the FCA (Fuel Control Actua-
tor). The other passage sends fuel to the cascade
overflow valve. The overflow valve sends some fuel to
a lubrication passage. The rest of the fuel is sent to a
drain passage which connects to an external fuel
line. This fuel line is connected to the same fuel filter
housing passage that the fuel transfer pump is con-
nected to.
Fuel that travels through the FCA is pressurized
by the fuel injection pump and sent through an
external high pressure fuel line to the fuel rail. At
the fuel rail, fuel is sent to the fuel injectors. If fuel
pressure in the fuel rail becomes excessive, the pres-
sure limiting valve opens and sends fuel through an
external fuel line. This line is connected to the fuel
filter housing at the fuel pump drain.
At the fuel injector, fuel that is not injected is used
for lubrication of the fuel injectors. This fuel then
travels through an internal passage in the rear of the
cylinder head, an then into an external fuel line. This
line is connected to the vehicles fuel return line, and
returns excess fuel back to the fuel tank.
Fig. 29 FILTER HOUSING (LATE)
1 - FILTER HOUSING
2 - FUEL HEATER AND THERMOSTAT
3 - FUEL HEATER MOUNTING SCREWS
4 - FUEL HEATER ELEC. CONNECTOR
5 - WIF SENSOR
6 - WIF SENSOR ELEC. CONNECTOR
7 - DRAIN HOSE
8 - DRAIN VALVE MOUNTING SCREWS
9 - DRAIN VALVE
14 - 78 FUEL DELIVERY - DIESELDR
WATER IN FUEL SENSOR (Continued)

FUEL INJECTION - DIESEL
TABLE OF CONTENTS
page page
ACCELERATOR PEDAL POSITION SENSOR
DESCRIPTION
DESCRIPTION (EARLY)................79
DESCRIPTION (LATE)..................79
OPERATION...........................79
REMOVAL.............................79
INSTALLATION.........................82
CAMSHAFT POSITION SENSOR
DESCRIPTION.........................82
OPERATION...........................82
REMOVAL.............................83
INSTALLATION.........................83
CRANKSHAFT POSITION SENSOR
DESCRIPTION.........................83
OPERATION...........................83
REMOVAL.............................84
INSTALLATION.........................84
FUEL CONTROL ACTUATOR
DESCRIPTION.........................85
OPERATION...........................85
REMOVAL.............................85
INSTALLATION.........................85
FUEL INJECTOR
DESCRIPTION.........................85
OPERATION...........................86
REMOVAL.............................87
INSTALLATION.........................87
FUEL INJECTOR RAIL
DESCRIPTION.........................89
OPERATION...........................89REMOVAL.............................89
INSTALLATION.........................90
INLET AIR TEMPERATURE SENSOR/
PRESSURE SENSOR
DESCRIPTION.........................90
OPERATION...........................90
REMOVAL.............................90
INSTALLATION.........................90
INTAKE AIR HEATER
DESCRIPTION.........................91
OPERATION...........................91
REMOVAL.............................91
INSTALLATION.........................91
INTAKE AIR HEATER RELAY
DESCRIPTION.........................92
OPERATION...........................92
REMOVAL.............................93
INSTALLATION.........................93
INTAKE AIR TEMPERATURE SENSOR/MAP
SENSOR
DESCRIPTION.........................93
OPERATION...........................93
REMOVAL.............................93
INSTALLATION.........................94
MAP SENSOR
DESCRIPTION.........................94
THROTTLE CONTROL CABLE
REMOVAL.............................94
INSTALLATION.........................96
ACCELERATOR PEDAL
POSITION SENSOR
DESCRIPTION
DESCRIPTION (EARLY)
The APPS assembly is located at the top-left-front
of the engine. A plastic cover is used to cover the
assembly. The actual sensor is located behind its
mounting bracket.
DESCRIPTION (LATE)
The Accelerator Pedal Position Sensor (APPS)
assembly is located under the vehicle battery tray. A
cable connects the assembly to the accelerator pedal.A plastic cover with a movable door is used to cover
the assembly.
OPERATION
The Accelerator Pedal Position Sensor (APPS) is a
linear potentiometer. It provides the Engine Control
Module (ECM) with a DC voltage signal proportional
to the angle, or position of the accelerator pedal.
REMOVAL
Early Diesel Engines
The APPS is serviced (replaced) as one assembly
including the lever, brackets and sensor. The APPS is
calibrated to its mounting bracket. The APPS assem-
bly is located at left-front of engine below plastic
cable/lever/linkage cover (Fig. 1).
DRFUEL INJECTION - DIESEL 14 - 79

N´m (14 in. lbs.).Be very careful not to over-
tighten these nuts as damage to fuel injector
will occur.
(9) Install exhaust rocker arm assembly.
(10) Set exhaust valve lash. Refer to Engine.
(11) Install high pressure connector and its
retainer nut. Tighten nut to 50 N´m (37 ft. lbs.)
torque.
(12) Install high pressure fuel line. Refer to Fuel
Line Installation.
(13) Install valve cover. Refer to Engine.
(14) Install breather assembly.
(15) Connect negative battery cables to both bat-
teries.
FUEL INJECTOR RAIL
DESCRIPTION
The fuel injector rail is bolted to the top of the
intake manifold.
OPERATION
The fuel rail is used as a distribution device to
supply high-pressure fuel to the high-pressure fuel
lines.
REMOVAL
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and pos-
sible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Disconnect both negative battery cables at both
batteries. Isolate ends of both cables.
(2) Disconnect electrical connector at fuel pressure
sensor.
(3) Remove banjo bolt at fuel limiting valve and
remove fuel limiting valve.
(4) Disconnect necessary wiring harness retention
clips from intake manifold.
(5) Lift 2 rubber covers to gain access to positive
(+), intake heater cable nuts. Remove 2 nuts and
remove 2 cables from studs.
(6) Carefully remove 4 high-pressure fuel lines
from top of injector rail engine. Note position of each
line while removing.Do not bend lines while
removing.
CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE LINES ATTACHED TO A SEPA-
RATE FITTING, USE A BACK-UP WRENCH ON FIT-
TING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.
(7) Carefully remove 2 high-pressure fuel lines at
each end of injector rail. Note position of each line
while removing.Do not bend lines while remov-
ing.
Fig. 21 MEASURING INJECTOR SEALING WASHER
(SHIM)
1 - SHIM
Fig. 22 CLEANING CYLINDER HEAD INJECTOR
BORE - TYPICAL BORE
1 - TYPICAL INJECTOR BORE
2 - WIRE BRUSH
DRFUEL INJECTION - DIESEL 14 - 89
FUEL INJECTOR (Continued)