fuel cap DODGE RAM 2003 Service Service Manual

CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate rail
halves at connector tubes (Fig. 19). Due to design
of tubes, it does not use any clamps. Never attempt
to install a clamping device of any kind to tubes.
When removing fuel rail assembly for any reason,
be careful not to bend or kink tubes.
(1) Remove fuel tank filler tube cap.
(2) Perform Fuel System Pressure Release Proce-
dure.
(3) Remove negative battery cable at battery.
(4) Remove air duct at throttle body air box.
(5) Remove air box at throttle body.
(6) Remove air resonator mounting bracket at
front of throttle body (2 bolts).
(7) Disconnect fuel line latch clip and fuel line at
fuel rail. A special tool will be necessary for fuel line
disconnection. Refer to Quick-Connect Fittings.
(8) Remove necessary vacuum lines at throttle
body.
(9) Disconnect electrical connectors at all 8 fuel
injectors. To remove connector refer to (Fig. 17). Push
red colored slider away from injector (1). While push-
ing slider, depress tab (2) and remove connector (3)
from injector. The factory fuel injection wiring har-
ness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. If harness is not
tagged, note wiring location before removal.
(10) Disconnect electrical connectors at all throttle
body sensors.
(11) Remove 8 ignition coils. Refer to Ignition Coil
Removal/Installation.
(12) Remove 4 fuel rail mounting bolts (Fig. 19).
(13) Gently rock and pullleftside of fuel rail until
fuel injectors just start to clear machined holes in
cylinder head. Gently rock and pullrightside of rail
until injectors just start to clear cylinder head holes.
Repeat this procedure (left/right) until all injectors
have cleared cylinder head holes.
(14) Remove fuel rail (with injectors attached)
from engine.
(15) If fuel injectors are to be removed, refer to
Fuel Injector Removal/Installation.
5.7L V-8
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING FUEL RAIL, FUEL SYSTEM
PRESSURE MUST BE RELEASED.
Fig. 17 REMOVE/INSTALL INJECTOR CONNECTOR
Fig. 18 FUEL RAIL REMOVE/INSTALL - 3.7L V-6
1 - MOUNTING BOLTS (4)
2 - QUICK-CONNECT FITTING
3 - FUEL RAIL
4 - INJ. #1
5 - INJ. #3
6 - INJ. #5
7 - INJ. #2
8 - INJ. #4
9 - INJ. #6
10 - CONNECTOR TUBE
14 - 14 FUEL DELIVERY - GASDR
FUEL RAIL (Continued)

CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate rail
halves at connector tube (Fig. 20). Due to design of
tube, it does not use any clamps. Never attempt to
install a clamping device of any kind to tube. When
removing fuel rail assembly for any reason, be care-
ful not to bend or kink tube.
(1) Remove fuel tank filler tube cap.
(2) Perform Fuel System Pressure Release Proce-
dure.
(3) Remove negative battery cable at battery.
(4) Remove flex tube (air cleaner housing to
engine).
(5) Remove air resonator box at throttle body.
(6) Disconnect all spark plug cables from all spark
plugs and ignition coils. Do not remove cables fromcable routing tray. Note original cable positions while
removing (Fig. 22).
(7) Remove spark plug cable tray from engine by
releasing 4 retaining clips (Fig. 21). Remove tray and
cables from engine as an assembly.
(8) Disconnect electrical connectors at all 8 igni-
tion coils. Refer to Ignition Coil Removal/Installation.
(9) Disconnect fuel line latch clip and fuel line at
fuel rail. A special tool will be necessary for fuel line
disconnection. Refer to Quick-Connect Fittings.
(10) Disconnect electrical connectors at all 8 fuel
injectors. To remove connector refer to (Fig. 17). Push
red colored slider away from injector (1). While push-
ing slider, depress tab (2) and remove connector (3)
from injector. The factory fuel injection wiring har-
ness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. If harness is not
tagged, note wiring location before removal.
(11) Disconnect electrical connectors at all throttle
body sensors.
(12) Remove 4 fuel rail mounting bolts and hold-
own clamps (Fig. 20).
(13) Gently rock and pullleftside of fuel rail until
fuel injectors just start to clear machined holes in
intake manifold. Gently rock and pullrightside of
rail until injectors just start to clear intake manifold
head holes. Repeat this procedure (left/right) until all
injectors have cleared machined holes.
(14) Remove fuel rail (with injectors attached)
from engine.
(15) If fuel injectors are to be removed, refer to
Fuel Injector Removal/Installation.
5.9L V-8
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH ENGINE TURNED
OFF). BEFORE SERVICING FUEL RAIL ASSEMBLY,
FUEL SYSTEM PRESSURE MUST BE RELEASED.
To release fuel pressure, refer to Fuel System Pres-
sure Release Procedure found in this group.
CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate the rail
halves at the connecting hose (Fig. 24). Due to the
design of this connecting hose, it does use any
clamps. Never attempt to install a clamping device
of any kind to the hose. When removing the fuel rail
assembly for any reason, be careful not to bend or
kink the connecting hose.
(1) Remove negative battery cable at battery.
(2) Remove air cleaner.
(3) Perform fuel pressure release procedure.
(4) Remove throttle body from intake manifold.
Refer to Throttle Body Removal/Installation.
Fig. 19 FUEL RAIL REMOVE/INSTALL - 4.7L V-8
1 - MOUNTING BOLTS (4)
2 - INJ.#7
3 - INJ.#5
4 - QUICK-CONNECT FITTING
5 - INJ.#3
6 - FUEL INJECTOR RAIL
7 - INJ.#1
8 - CONNECTOR TUBE
9 - INJ.#2
10 - INJ.#4
11 - INJ.#6
12 - INJ.#8
13 - PRESSURE TEST PORT CAP
DRFUEL DELIVERY - GAS 14 - 15
FUEL RAIL (Continued)

(13) Start engine and check for leaks.
8.0L V-10
(1) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(2) Install injector(s) and injector clip(s) to fuel
rail.
NOTE: The fuel injector electrical connectors on all
10 injectors should be facing to right (passenger)
side of vehicle (Fig. 27).
(3) Position fuel rail/fuel injector assembly to injec-
tor openings on intake manifold.
(4) Guide each injector into intake manifold. Be
careful not to tear injector o-ring.
(5) Push therightfuel rail down until fuel injec-
tors have bottomed on injector shoulder. Push the
leftfuel rail down until fuel injectors have bottomed
on injector shoulder.
(6) Install six fuel rail mounting bolts into lower
half of intake manifold. Tighten bolts to 15 N´m (136
in. lbs.) torque.
(7) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 26). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector. The injector wir-
ing harness is numerically tagged.
(8) Install upper half of intake manifold. Refer to
Engines for procedures.
(9) Connect main fuel line at fuel rail. Refer to
Quick-Connect Fittings for procedures.
(10) Install ignition coil pack and bracket assem-
bly at intake manifold and right engine valve cover
(four bolts).
(11) Install throttle body to intake manifold. Refer
to Throttle Body Removal / Installation.
(12) Install throttle body linkage to throttle body.
(13) Install air cleaner tube and housing.
(14) Install negative battery cable at battery.
(15) Start engine and check for leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module, and (if equipped) cer-
tain ORVR components.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.Two check (control) valves are mounted into the
top of the fuel tank. Refer to Fuel Tank Check Valve
for additional information.
An evaporation control system is connected to the
fuel tank to reduce emissions of fuel vapors into the
atmosphere. When fuel evaporates from the fuel
tank, vapors pass through vent hoses or tubes to a
charcoal canister where they are temporarily held.
When the engine is running, the vapors are drawn
into the intake manifold. Certain models are also
equipped with a self-diagnosing system using a Leak
Detection Pump (LDP) and/or an On-Board Refueling
Vapor Recovery (ORVR) system. Refer to Emission
Control System for additional information.
REMOVAL- EXCEPT DIESEL
Fuel Tank Draining
WARNING: THE FUEL SYSTEM MAY BE UNDER
CONSTANT FUEL PRESSURE EVEN WITH THE
ENGINE OFF. THIS PRESSURE MUST BE
RELEASED BEFORE SERVICING FUEL TANK.
Two different procedures may be used to drain fuel
tank: through the fuel fill fitting on tank, or using
the DRBtscan tool. 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.
The quickest draining procedure involves removing
the rubber fuel fill hose.
As an alternative procedure, the electric fuel pump
may be activated allowing tank to be drained at fuel
rail connection. Refer to DRB scan tool for fuel pump
activation procedures. Before disconnecting fuel line
at fuel rail, release fuel pressure. Refer to the Fuel
System Pressure Release Procedure for procedures.
Attach end of special test hose tool number 6541,
6539, 6631 or 6923 at fuel rail disconnection (tool
number will depend on model and/or engine applica-
tion). Position opposite end of this hose tool to an
approved gasoline draining station. Activate fuel
pump and drain tank until empty.
If electric fuel pump is not operating, fuel must be
drained through fuel fill fitting at tank. Refer to fol-
lowing procedures.
(1) Release fuel system pressure.
(2) Raise vehicle.
(3) Thoroughly clean area around fuel fill fitting
and rubber fuel fill hose at tank.
(4) If vehicle is equipped with 4 doors and a 6 foot
(short) box, remove left-rear tire/wheel.
(5) Loosen clamp (Fig. 28) and disconnect rubber
fuel fill hose at tank fitting. Using an approved gas
holding tank, drain fuel tank through this fitting.
14 - 20 FUEL DELIVERY - GASDR
FUEL RAIL (Continued)

FUEL DELIVERY - DIESEL
DESCRIPTION - DIESEL FUEL SYSTEM
The fuel system used on the Cummins engine is an
electronically controlled, Bosch HPCR (High-Pressure
Common Rail) system. The HPCR system consists of
five main components:
²Electric Fuel Transfer (lift) Pump
²Fuel Pump/Gear Pump (attached to fuel injec-
tion pump)
²High-Pressure Fuel Injection Pump
²Fuel Injection Rail
²Fuel Injectors
Also to be considered as part of the overall fuel
system are:
²Accelerator Pedal
²Air Cleaner Housing/Element
²Fuel Drain Manifold (passage)
²Fuel Drain Valve (at filter)
²Fuel Filter/Water Separator
²Fuel Heater
²Fuel Heater Relay
²Fuel Level (gauge) Sending Unit
²Fuel Tank
²Fuel Tank Module (containing fuel gauge send-
ing unit and separate fuel filter located at bottom of
tank module)
²Fuel Tank Filler/Vent Tube Assembly
²Fuel Tank Filler Tube Cap
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 Fuel Line Fittings
²Throttle Cable
²Water Draining (maintenance)
²Water-In-Fuel (WIF) Sensor
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
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 FCA (Fuel Control Actuator).
The FCA 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 FCA 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.
Some fuel system components are shown in.
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 160,000 KPA (23,206
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.
Certain fuel system components can be found in
(Fig. 1), or (Fig. 2).
STANDARD PROCEDURE
STANDARD PROCEDURES - WATER DRAINING
AT FUEL FILTER
Refer to Fuel Filter/Water Separator removal/in-
stallation for procedures.
DRFUEL DELIVERY - DIESEL 14 - 57

STANDARD PROCEDURES - CLEANING FUEL
SYSTEM PARTS
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.
Fig. 1 DIESEL FUEL SYSTEM COMPONENTS
1 - ENGINE COOLANT TEMPERATURE (ECT) SENSOR 14 - FUEL SUPPLY LINE (LOW-PRESSURE, TO ENGINE)
2 - THROTTLE LEVER BELLCRANK AND APPS (ACCELERATOR
PEDAL POSITION SENSOR)15 - FUEL RETURN LINE CONNECTION (TO FUEL TANK)
3 - INTAKE MANIFOLD AIR HEATER/ELEMENTS 16 - FUEL DRAIN TUBE
4 - FUEL PRESSURE SENSOR 17 - OIL PRESSURE SENSOR
5 - FUEL LIMITING VALVE 18 - ENGINE CONTROL MODULE (ECM)
6 - HIGH-PRESSURE FUEL LINES 19 - FUEL INJECTION PUMP
7 - FUEL HEATER 20 - CRANKSHAFT POSITION (ENGINE SPEED) SENSOR
8 - HIGH-PRESSURE FUEL INJECTOR RAIL 21 - CAMSHAFT POSITION SENSOR (CMP)
9 - FUEL HEATER TEMPERATURE SENSOR (THERMOSTAT) 22 - FUEL CONTROL ACTUATOR (FCA)
10 - FUEL FILTER/WATER SEPARATOR 23 - CASCADE OVERFLOW VALVE
11 - FUEL TRANSFER (LIFT) PUMP
12 - FUEL DRAIN MANIFOLD
13 - DRAIN VALVE
14 - 58 FUEL DELIVERY - DIESELDR
FUEL DELIVERY - DIESEL (Continued)

SPECIFICATIONS
FUEL SYSTEM PRESSURE - DIESEL
DESCRIPTION PRESSURE
Fuel Transfer (Lift) Pump Pressure Minimum 9.5 psi
FUEL INJECTOR FIRING ORDER - DIESEL
1±5±3±6±2±4
SPECIAL TOOLS
DIESEL FUEL SYSTEM
FUEL PRESSURE TEST ADAPTER - # 9012
FUEL PRESSURE TEST ADAPTER - #9014
FUEL INJECTOR REMOVER - #9010
PRESSURE CAP - #9011
FUEL PRESSURE TEST ADAPTER - #9013
14 - 60 FUEL DELIVERY - DIESELDR
FUEL DELIVERY - DIESEL (Continued)

(b) Disconnect electrical connector.
(c) Remove two T-15 Torx head mounting screws
from fuel heater element.
(d) Remove fuel filter cover and filter element.
(e) Remove fuel heater.
(8)Drain Valve Replacement:The drain valve
assembly is located on the side of the fuel filter hous-
ing (Fig. 3) or (Fig. 4).
(a) Disconnect drain hose from the fuel drain
valve.
(b) Remove 4 drain valve mounting screws (T-15
Torx head).
(c) Remove drain valve from filter housing.
INSTALLATION
Refer to maintenance schedules for recommended
fuel filter replacement intervals.
(1) Thoroughly clean inside of filter housing, filter
cap and all related components.
(2)Fuel Filter:
(a)The engine has a self-priming low-pres-
sure fuel system. Refer to Standard Proce-
dures-Fuel System Priming.
(b) Install new o-ring to canister lid and lubri-
cate o-ring with 30W oil.
Fig. 3 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
Fig. 4 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
Fig. 5 FILTER COVER (LID)
1 - FILTER COVER
2 - ATTACH SOCKET HERE
14 - 62 FUEL DELIVERY - DIESELDR
FUEL FILTER / WATER SEPARATOR (Continued)

(c) Position new element to canister lid. Place
this assembly into canister by rotating clockwise.
(d) Tighten cap to 34 N´m (25 ft. lbs.) torque. Do
not overtighten cap.
(3)Water-In-Fuel (WIF) Sensor:
(a) Install new o-ring seal to WIF sensor.
(b) Apply a light film of clean diesel oil to o-ring
seal.
(c) Install sensor into housing.
(d) Tighten sensor to 4.5 N´m (39 in. lbs.) torque.
(e) Connect electrical connector to WIF sensor.
(4)Fuel Heater Element:
(a) Install fuel heater into fuel filter housing.
(b) Install fuel heater thermostat into fuel filter
housing.
(c) Install fuel heater mounting screws and
tighten to 1-1.5 N´m torque.
(d) Connect electrical connector to fuel heater
thermostat.
(e) Install new filter cover O-ring onto fuel filter
housing cover and lubricate with 30W oil.
(f) Tighten fuel filter housing cover (lid) to 34
N´m (25 ft. lbs.).
(5)Drain Valve:
(a) Install 2 new o-rings to valve and filter hous-
ing.
(b) Lubricate with silicon grease.
(c) Install fuel drain valve.
(d) Install 4 mounting screws and tighten to
1±1.5 N´m (8±13 in. lbs.) torque.
(e) Connect drain hose to drain valve.
(6) Start engine and check for leaks.
FUEL HEATER
DESCRIPTION
The fuel heater assembly is located on the side of
the fuel filter housing (Fig. 3) or (Fig. 4).
The heater/element assembly is equipped with a
temperature sensor (thermostat) that senses fuel
temperature. This sensor is attached to the fuel heat-
er/element assembly.
OPERATION
The fuel heater is used to prevent diesel fuel from
waxing during cold weather operation.
When the temperature is below 45  8 degrees F,
the temperature sensor allows current to flow to the
heater element warming the fuel. When the temper-
ature is above 75  8 degrees F, the sensor stops cur-
rent flow to the heater element.
Battery voltage to operate the fuel heater element
is supplied from the ignition switch and through the
fuel heater relay. Also refer to Fuel Heater Relay.The fuel heater element and fuel heater relay
are not computer controlled.
The heater element operates on 12 volts, 300 watts
at 0 degrees F.
DIAGNOSIS AND TESTING - FUEL HEATER
The fuel heater is used to prevent diesel fuel from
waxing during cold weather operation.
NOTE: The fuel heater element, fuel heater relay
and fuel heater temperature sensor are not con-
trolled by the Engine Control Module (ECM), or the
Powertrain Control Module (PCM).
A malfunctioning fuel heater can cause a wax
build-up in the fuel filter/water separator. Wax
build-up in the filter/separator can cause engine
starting problems and prevent the engine from rev-
ving up. It can also cause blue or white fog-like
exhaust. If the heater is not operating in cold tem-
peratures, the engine may not operate due to fuel
waxing.
The fuel heater assembly is located on the side of
fuel filter housing.
The heater assembly is equipped with a built-in
fuel temperature sensor (thermostat) that senses fuel
temperature. When fuel temperature drops below 45
degrees   8 degrees F, the sensor allows current to
flow to built-in heater element to warm fuel. When
fuel temperature rises above 75 degrees   8 degrees
F, the sensor stops current flow to heater element
(circuit is open).
Voltage to operate fuel heater element is supplied
from ignition switch, through fuel heater relay (also
refer to Fuel Heater Relay), to fuel temperature sen-
sor and on to fuel heater element.
The heater element operates on 12 volts, 300 watts
at 0 degrees F. As temperature increases, power
requirements decrease.
A minimum of 7 volts is required to operate fuel
heater. The resistance value of heater element is less
than 1 ohm (cold) and up to 1000 ohms warm.
TESTING
(1) Disconnect electrical connector from thermostat
(Fig. 3) or (Fig. 4).
Ambient temperature must be below circuit close
temperature, If necessary, induce this ambient tem-
perature by placing ice packs on thermostat to pro-
duce an effective ambient temperature below circuit
close temperature. For first check of thermostat you
can hear click of thermostat when circuit closes.
Measure resistance across two pins. Operating
range is 0.3 Ð 0.45 Ohms.
(2) If resistance is out of range, remove thermostat
and check resistance across terminal connections of
DRFUEL DELIVERY - DIESEL 14 - 63
FUEL FILTER / WATER SEPARATOR (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)

INSTALLATION
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) Inspect pump mounting surfaces at pump and
mounting flange for nicks, cuts or damage. Inspect
o-ring surfaces for nicks, cuts or damage.
(2) Clean injection pump mounting flange at gear
housing. Also clean front of injection pump.
(3) Install new rubber o-ring into machined groove
(Fig. 14) at pump mounting area.
Fig. 14 FUEL INJECTION PUMP REMOVAL/INSTALLATION
1 - PUMP DRIVE GEAR NUT
2 - WASHER
3 - PUMP DRIVE GEAR
4 - RUBBER O-RING
5 - FUEL INJECTION PUMP6 - PUMP MOUNTING NUTS (3)
7 - PUMP MOUNTING STUDS (3)
8 - O-RING MACHINED GROOVE
9 - FRONT TIMING GEAR COVER
Fig. 13 DRIVE GEAR REMOVAL
1 - FRONT TIMING GEAR COVER
2 - GEAR PULLER TOOL
DRFUEL DELIVERY - DIESEL 14 - 67
FUEL INJECTION PUMP (Continued)