Dodge Fuel 3500 2005, Fuel 2500 2005, Fuel 1500 2005 Service Manual

DR/DH FUEL SYSTEM 14 - 1

FUEL SYSTEM

TABLE OF CONTENTS

page page

FUEL DELIVERY - GAS ....................1

FUEL INJECTION - GAS ...................42

FUEL DELIVERY - GAS

TABLE OF CONTENTS

page page

FUEL DELIVERY - GAS

DESCRIPTION ..........................1

OPERATION ............................4

STANDARD PROCEDURE - FUEL SYSTEM

PRESSURE RELEASE ...................4

SPECIFICATIONS

FUEL SYSTEM PRESSURE ...............5

TORQUE - FUEL SYSTEM - EXCEPT

DIESEL ..............................5

SPECIAL TOOLS

FUEL SYSTEM ........................7

FUEL FILTER/PRESSURE REGULATOR

DESCRIPTION ..........................8

OPERATION ............................8

SENSOR - FUEL LEVEL SENDING UNIT

DESCRIPTION ..........................8

OPERATION ............................8

REMOVAL ..............................9

INSTALLATION .........................10

LINES, FUEL

DESCRIPTION .........................10

FITTING, QUICK CONNECT

DESCRIPTION .........................10

STANDARD PROCEDURE - QUICK-CONNECT

FITTINGS ............................10

MODULE-FUEL PUMP

DESCRIPTION .........................15

FUEL DELIVERY - DIESEL .................98

FUEL INJECTION - DIESEL ...............126

OPERATION ...........................15

MODULE - FUEL PUMP

DESCRIPTION .........................16

OPERATION ...........................16

REMOVAL .............................16

INSTALLATION .........................17

RAIL - FUEL

DESCRIPTION .........................17

OPERATION ...........................17

REMOVAL

3.7L V-6 .............................17

4.7L V-8 .............................18

5.7L V-8 .............................20

8.3L - SRT-10 .........................23

INSTALLATION

3.7L V-6 .............................27

5.7L V-8 .............................28

4.7L V-8 .............................29

8.3L - SRT-10 .........................29

TANK - FUEL

DESCRIPTION .........................30

OPERATION ...........................30

REMOVAL- EXCEPT DIESEL ..............30

INSTALLATION - EXCEPT DIESEL ..........36

FILTER - INLET

REMOVAL .............................40

INSTALLATION .........................41

FUEL DELIVERY - GAS

DESCRIPTION

The fuel delivery system consists of:

• a fuel pump module containing the electric fuel pump, fuel filter/fuel pressure regulator, fuel gauge sending unit (fuel level sensor) and a secondary fuel filter located at the bottom of the pump module

• fuel tubes/lines/hoses

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• a combination fuel filter/fuel pressure regulator

• quick-connect fittings

• fuel injector rail

• fuel tank

• fuel tank filler/vent tube assembly

• fuel tank filler tube cap

• accelerator pedal

• throttle cable

Certain fuel delivery components can be found in the following graphics:

DR/DH FUEL DELIVERY - GAS 14 - 3

14 - 4 FUEL DELIVERY - GAS DR/DH

OPERATION

Fuel is returned through the fuel pump module and back into the fuel tank through the fuel filter/fuel pressure regulator. A separate fuel return line from the engine to the tank is not used.

The fuel tank assembly consists of: the fuel tank, fuel pump module assembly, fuel pump module locknut/gasket, and fuel tank check valve (refer to Fuel Tank Check Valve for information).

A fuel filler/vent tube assembly using a pressure/vacuum, 1/4 turn fuel filler cap is used. The fuel filler tube contains a flap door located below the fuel fill cap.

Also to be considered part of the fuel system is the evaporation control system. This is designed to reduce the emission of fuel vapors into the atmosphere. The description and function of the Evaporative Control System is found in Emission Control Systems.

Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so.

STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE

Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port.

1. Remove fuel fill cap.

2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover.

3. Start and run engine until it stalls.

4. Attempt restarting engine until it will no longer run.

5. Turn ignition key to OFF position.

CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber.

6. Unplug connector from any fuel injector.

7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal.

8. Connect other end of jumper wire to positive side of battery.

DR/DH FUEL DELIVERY - GAS 14 - 5

9. Connect one end of a second jumper wire to remaining injector terminal.

CAUTION: Powering an injector for more than a few seconds will permanently damage the injector.

10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds.

11. Place a rag or towel below fuel line quick-connect fitting at fuel rail.

12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings.

13. Return fuel pump relay to PDC.

14. One or more Diagnostic Trouble Codes (DTC’s) may have been stored in PCM memory due to fuel pump relay

removal. The DRBT scan tool must be used to erase a DTC.

SPECIFICATIONS FUEL SYSTEM PRESSURE

58 psi +/- 2 psi

TORQUE - FUEL SYSTEM - EXCEPT DIESEL

DESCRIPTION N-m Ft. Lbs. In. Lbs.

Accelerator Pedal Bracket Mounting 12 - 105

Accelerator Pedal Position Sensor Bracket-to-

Battery Tray Bolts Crankshaft Position Sensor - 3.7L 28 21 Crankshaft Position Sensor - 4.7L 28 21 Crankshaft Position Sensor - 5.7L 12 - 105 (+/-20)

Camshaft Position Sensor - 3.7L 12 - 106 Camshaft Position Sensor - 4.7L 12 - 106

Camshaft Position Sensor - 5.7L 12 9 105 (+/-) 20 Engine Coolant Temperature Sensor - 3.7L 11 - 96 Engine Coolant Temperature Sensor - 4.7L 11 - 96 Engine Coolant Temperature Sensor - 5.7L 11 - 96

EVAP Canister- to-Bracket Nuts 8.5 - 75

EVAP Canister-to-frame bolts 34 25

Fuel Filler Hose Clamp at Tank 3 - 30

Fuel Filler Housing-to-Body Screws 2 - 17

Fuel Pump Module Lock Ring 54 40 Fuel Rail Mounting Bolts - 3.7L 11 - 100 Fuel Rail Mounting Bolts - 4.7L 11 - 100 Fuel Rail Mounting Bolts - 5.7L 11 - 100 Fuel Rail Mounting Bolts - 8.3L 12 - 105

Fuel Tank Mounting Straps 41 30 IAC Motor Mounting Screws - 3.7L 7 - 60 IAC Motor Mounting Screws - 4.7L 7 - 60

Leak Detection Pump Mounting Bolt 8.5 - 75 Map Sensor Mounting Screws - 3.7L 3 - 25 Map Sensor Mounting Screws - 4.7L 3 - 25

PCM-to-Mounting Bracket Mounting Screws 4 - 35

Power Steering Pressure Switch - 3.7L 14-22 - 124-195

3-30

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DESCRIPTION N-m Ft. Lbs. In. Lbs.

Power Steering Pressure Switch - 4.7L 14-22 - 124-195

TPS Mounting Screws - 3.7L 7 - 60

TPS Mounting Screws - 4.7L 7 - 60 Throttle Body Mounting Bolts - 3.7L 11 - 100 Throttle Body Mounting Bolts - 4.7L 12 - 105 Throttle Body Mounting Bolts - 5.7L 12 - 105

Oxygen Sensors 30 22 -

Ignition Coil Mounting Bolts 11 - 100

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SPECIAL TOOLS FUEL SYSTEM

LOCKRING REMOVER/INSTALLER #9340

FUEL PRESSURE TESTER - #8978

TEST KIT, FUEL PRESSURE #5069

SPANNER WRENCH - #6856

FITTING, AIR METERING - #6714

O2S (OXYGEN SENSOR) REMOVER/INSTALLER -

#C-4907

ADAPTERS, FUEL PRESSURE TEST - #6539

AND/OR #6631

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FUEL FILTER/PRESSURE REGULATOR

DESCRIPTION

A combination fuel filter and fuel pressure regulator (3) is used on all engines. It is located on the top of the fuel pump module. A separate frame mounted fuel filter is not used with any engine.

OPERATION

Fuel Pressure Regulator Operation: The pressure regulator is a mechanical device that is not controlled by

engine vacuum or the Powertrain Control Module (PCM). The regulator is calibrated to maintain fuel system operating pressure of approximately 58 ± 2 psi at the fuel injec-

tors. It contains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter is also part of the assembly.

Fuel is supplied to the filter/regulator by the electric fuel pump through an opening tube at the bottom of filter/regulator.

The regulator acts as a check valve to maintain some fuel pressure when the engine is not operating. This will help to start the engine. A second check valve is located at the outlet end of the electric fuel pump. Refer to Fuel Pump

- Description and Operation for more information.

If fuel pressure at the pressure regulator exceeds approximately 60 psi, an internal diaphragm opens and excess fuel pressure is routed back into the tank through the bottom of pressure regulator.

SENSOR - FUEL LEVEL SENDING UNIT

DESCRIPTION

The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card).

OPERATION

The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation.

For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V

power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about

8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel

DR/DH FUEL DELIVERY - GAS 14 - 9

level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit.

Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information.

For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/ setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity.

REMOVAL

The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module.

1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation.

2. Disconnect 4–wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in 8W Wiring for tool part numbers.

3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks.

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INSTALLATION

1. Connect necessary wiring into electrical connectors. Connect 4–wire electrical connector to pump module.

2. Position sending unit to pump module. Slide and snap into place.

3. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation.

LINES, FUEL

DESCRIPTION

Also refer to Quick-Connect Fittings.

WARNING: THE FUEL SYSTEM MAY BE UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS, LINES, OR MOST COMPONENTS, FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE.

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 contaminated 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 rubber 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 highpressure fuel leaks.

Use new original equipment type hose clamps.

FITTING, QUICK CONNECT

DESCRIPTION

Different types of quick-connect fittings are used to attach the various fuel system components, lines and tubes. These are: a single-button type, a two-button type, a pinch type, 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 special tool for disconnection and removal. Refer to Quick-Connect Fittings Removal/Installation for more information.

CAUTION: Before separating a quick-connect fitting, pay attention to what type of fitting is being used by referring to Quick-Connect Fitting Removal. This will prevent unnecessary fitting or fitting latch breakage.

CAUTION: The interior components (o-rings, clips) of quick-connect fittings are not serviced separately, but new plastic spacers and latches 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 PROCEDURE - QUICK-CONNECT FITTINGS

DISCONNECTING

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSE, FITTING OR LINE, FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO FUEL SYSTEM PRESSURE RELEASE PROCEDURE.

DR/DH FUEL DELIVERY - GAS 14 - 11

1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure.

2. Disconnect negative battery cable from battery.

3. Clean fitting of any foreign material before disassembly.

4. Single–Button Type Fitting: This type of fitting is equipped with a single push-button (2) located on the quick-connect fitting.

5. The push-button is attached to two internal latches (1). To disconnect, press on push-button with your thumb and unlatch fitting from fuel line. Special tools are not required for disconnection. DO NOT

ATTEMPT TO PRY OR PULL UP ON PUSH-BUTTON. LATCHES WILL BE BROKEN.

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6. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure.

7. Disconnect negative battery cable from battery.

8. Clean fitting of any foreign material before disassembly.

9. 2–Button Type Fitting: This type of fitting (1) is equipped with a push-button located on each side of quick-connect fitting (2). Press on both buttons simultaneously for removal. Special tools are not required for disconnection.

10. Pinch-Type Fitting: This fitting (1) is equipped

with two finger tabs (2). Pinch both tabs together while removing fitting. Special tools are not required for disconnection.

11. Single-Tab Type Fitting: This type of fitting (3) is

equipped with a single pull tab (1). The tab is removable. After tab is removed, quick-connect fitting can be separated from fuel system component. Special tools are not required for disconnection.

DR/DH FUEL DELIVERY - GAS 14 - 13

12. Press release tab on side of fitting to release pull

tab (1). If release tab is not pressed prior to

releasing pull tab, pull tab will be damaged.

13. While pressing release tab on side of fitting, use

screwdriver (2) to pry up pull tab.

14. Raise pull tab until it separates from quick-con-

nect fitting.

15. Two-Tab Type Fitting: This type of fitting (2) is

equipped with tabs located on both sides of fitting (1). The tabs are supplied for disconnecting quickconnect fitting from component being serviced.

a. To disconnect quick-connect fitting, squeeze

plastic retainer tabs (1) against sides of quickconnect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer.

b. Pull fitting from fuel system component being

serviced.

c. The plastic retainer will remain on component

being serviced after fitting is disconnected. The o-rings and spacer will remain in quick-connect fitting connector body.

16. Plastic Retainer Ring Type Fitting: This type of

fitting can be identified by the use of a full-round plastic retainer ring (4) usually black in color.

a. To release fuel system component from quick-

connect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting (6). With plastic ring depressed, pull fitting from component.

The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection.

b. After disconnection, plastic retainer ring will

remain with quick-connect fitting connector body.

c. Inspect fitting connector body, plastic retainer

ring and fuel system component for damage. Replace as necessary.

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17. Latch Clips — Type 1: Depending on vehicle

model and engine, 2 different types of safety latch clips are used. Type-1 (4) is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/ fuel rail connection, or to join fuel lines together.

18. Pry up on latch clip with a screwdriver (3).

19. Slide latch clip toward fuel rail while lifting with

screwdriver.

20. Insert special fuel line removal tool (Snap-On

number FIH 9055-1 or equivalent) into fuel line (1). Use tool to release locking fingers in end of line.

21. With special tool still inserted, pull fuel line from

fuel rail.

22. After disconnection, locking fingers will remain

within quick-connect fitting at end of fuel line.

23. Disconnect quick-connect fitting from fuel system

component being serviced.

24. Latch Clips — Type 2: Depending on vehicle

model and engine, 2 different types of safety latch clips are used. Type-1 is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/ fuel rail connection, or to join fuel lines together.

25. Type 2: Separate and unlatch 2 small arms (1) on

end of clip and swing away from fuel line.

26. Slide latch clip toward fuel rail while lifting with

screwdriver.

DR/DH FUEL DELIVERY - GAS 14 - 15

27. Insert special fuel line removal tool (Snap-On

number FIH 9055-1 or equivalent) into fuel line (1). Use tool to release locking fingers in end of line.

28. With special tool still inserted, pull fuel line from

fuel rail.

29. After disconnection, locking fingers will remain

within quick-connect fitting at end of fuel line.

30. Disconnect quick-connect fitting from fuel system

component being serviced.

CONNECTING

1. Inspect quick-connect fitting body and fuel system component for damage. Replace as necessary.

2. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil.

3. Insert quick-connect fitting into fuel tube or fuel system component until built-on stop on fuel tube or component rests against back of fitting.

4. Continue pushing until a click is felt.

5. Single-tab type fitting: Push new tab down until it locks into place in quick-connect fitting.

6. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.).

7. Latch Clip Equipped: Install latch clip (snaps into position). If latch clip will not fit, this indicates fuel line is

not properly installed to fuel rail (or other fuel line). Recheck fuel line connection.

8. Connect negative cable to battery.

9. Start engine and check for leaks.

MODULE-FUEL PUMP

DESCRIPTION

The electric fuel pump is located inside of the fuel pump module. A 12 volt, permanent magnet, electric motor powers the fuel pump. The electric fuel pump is not a separate, serviceable component.

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 bottom section of the fuel pump module contains a one-way check valve to prevent

fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline 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.

The electric fuel pump is not a separate, serviceable component.

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MODULE - FUEL PUMP

DESCRIPTION

The fuel pump module assembly is located on the top of the fuel tank. The complete assembly contains the following components:

• A combination fuel filter/fuel pressure regulator

• A separate fuel pick-up, or inlet filter

• An electric fuel pump

• A lockring to retain pump module to tank

• A soft gasket between tank flange and module

• A fuel gauge sending unit (fuel level sensor)

• Fuel line connection

The fuel gauge sending unit may be serviced separately. If the electrical fuel pump, primary inlet filter, fuel filter or fuel pressure regulator require service, the fuel pump module must be replaced.

OPERATION

Refer to Fuel Pump, Inlet Filter, Fuel Filter / Fuel Pressure Regulator and Fuel Gauge Sending Unit.

REMOVAL

WARNING: THE FUEL SYSTEM MAY BE UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING THE FUEL PUMP MODULE, THE FUEL SYSTEM PRESSURE MUST BE RELEASED.

1. Drain and remove fuel tank. Refer to Fuel Tank Removal/Installation.

2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose.

3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5).

4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3).

5. Rotate breaker bar counter-clockwise to remove lockring (5).

6. Remove lockring. The module will spring up slightly when lockring is removed.

7. Remove module from fuel tank. Be careful not to bend float arm while removing.

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INSTALLATION

1. Using a new seal (gasket), position fuel pump module into opening in fuel tank.

2. Position lockring (5) over top of fuel pump module.

3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle.

4. Install Special Tool 9340 (3) to lockring.

5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3).

6. Tighten lockring (clockwise) until all seven notches have engaged.

7. Install fuel tank. Refer to Fuel Tank Removal/Installation.

RAIL - FUEL

DESCRIPTION

The fuel injector rail is used to mount the fuel injectors to the engine.

OPERATION

High pressure from the fuel pump is routed to the fuel rail. The fuel rail then supplies the necessary fuel to each individual fuel injector.

A quick-connect fitting with a safety latch clip is used to attach the fuel line to the fuel rail. The fuel rail is not repairable.

CAUTION: The left and right sections of the fuel rail are connected with either a flexible connecting hose, or joints. Do not attempt to separate the rail halves at these connecting hose or joints. Due to the design of the connecting hose or joint, it does not use any clamps. Never attempt to install a clamping device of any kind to the hose or joint. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connecting hose or joint.

REMOVAL

3.7L V-6

WARNING: THE FUEL SYSTEM IS UNDER CONSTANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING FUEL RAIL, FUEL SYSTEM PRESSURE MUST BE RELEASED.

CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connector tubes. 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.

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1. Remove fuel tank filler tube cap.

2. Perform Fuel System Pressure Release Procedure. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY STANDARD PROCEDURE)

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 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE)

8. Remove necessary vacuum lines at throttle body.

9. Disconnect electrical connectors at all 6 fuel injectors. To remove connector refer to. Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness 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 6 ignition coils. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/IGNITION COIL - REMOVAL)

12. Remove 4 fuel rail mounting bolts (1).

13. Gently rock and pull left side of fuel rail until fuel

injectors just start to clear machined holes in cylinder head. Gently rock and pull right side 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 14 -

FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL).

4.7L V-8

WARNING: THE FUEL SYSTEM IS UNDER CONSTANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING FUEL RAIL, FUEL SYSTEM PRESSURE MUST BE RELEASED.

DR/DH FUEL DELIVERY - GAS 14 - 19

1. Remove fuel tank filler tube cap.

2. Perform Fuel System Pressure Release Procedure. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY STANDARD PROCEDURE)

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).

8. Remove necessary vacuum lines at throttle body.

9. Disconnect electrical connectors at all 8 fuel injectors. To remove connector refer to. Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness 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 8 - ELECTRICAL/IGNITION CONTROL/IGNITION COIL - REMOVAL)

14 - 20 FUEL DELIVERY - GAS DR/DH

12. Remove 4 fuel rail mounting bolts (1).

13. Gently rock and pull left side of fuel rail until fuel

14. Remove fuel rail (with injectors attached) from

engine.

15. If fuel injectors are to be removed, (Refer to 14 -

FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL).

5.7L V-8

WARNING: THE FUEL SYSTEM IS UNDER CONSTANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING FUEL RAIL, FUEL SYSTEM PRESSURE MUST BE RELEASED.

CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connector tube. 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 careful not to bend or kink tube.

DR/DH FUEL DELIVERY - GAS 14 - 21

1 - #8 COIL-TO- #5 SPARK PLUG (MARKED 5/8) 7 - CABLE TRAY 2 - #5 COIL-TO- #8 SPARK PLUG (MARKED 5/8) 8 - CLIPS (SPARK PLUG CABLE-TO-TRAY- RETENTION) 3 - #7 COIL-TO- #4 SPARK PLUG (MARKED 4/7) 9 - #2 COIL-TO- #3 SPARK PLUG (MARKED 2/3) 4 - #3 COIL-TO- #2 SPARK PLUG (MARKED 2/3) 10 - #6 COIL-TO- #1 SPARK PLUG (MARKED 1/6) 5 - #1 COIL-TO- #6 SPARK PLUG (MARKED 1/6) 11 - #4 COIL-TO- #7 SPARK PLUG (MARKED 4/7) 6 - CLIPS (TRAY-TO-MANIFOLD RETENTION)

1. Remove fuel tank filler tube cap.

2. Perform Fuel System Pressure Release Procedure. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE)

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 from cable routing tray. Note original cable positions while removing.

14 - 22 FUEL DELIVERY - GAS DR/DH

7. Remove spark plug cable tray from engine by releasing 4 retaining clips. Remove tray and cables from engine as an assembly.

8. Disconnect electrical connectors at all 8 ignition 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 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE)

10. Disconnect electrical connectors at all 8 fuel injec-

tors. To remove connector refer to. Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness 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.

DR/DH FUEL DELIVERY - GAS 14 - 23

12. Remove 4 fuel rail mounting bolts (2) and hold-

own clamps (3).

13. Gently rock and pull left side of fuel rail until fuel

injectors just start to clear machined holes in intake manifold. Gently rock and pull right side 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 14 -

FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL).

8.3L - SRT-10

1. Disconnect the electrical connector to the MAP sensor (2) and Coolant Temperature sensor (3).

2. Release fuel system pressure. Refer to Fuel Pressure Release Procedure in this section.

3. Disconnect negative battery cable.

4. Remove the air cleaner assembly, refer to the Engine/Air Intake System/Air Cleaner Housing for more information.

14 - 24 FUEL DELIVERY - GAS DR/DH

5. Disconnect the electrical connector to the TPS (1) and Idle Air Control.

6. Remove the wiring harness from the wiring clips under the throttle body.

7. Disconnect the electrical connector from the fuel injectors.

DR/DH FUEL DELIVERY - GAS 14 - 25

8. Disconnect the fuel line quick connector.

9. Remove the bolts for the fuel rail.

10. Pull fuel rail and injectors straight up and out of

the intake manifold.

14 - 26 FUEL DELIVERY - GAS DR/DH

11. Move the fuel rail forward and out from under the

intake manifold and throttle body.

12. Remove the fuel injector from the fuel rail.

DR/DH FUEL DELIVERY - GAS 14 - 27

INSTALLATION

3.7L V-6

1. If fuel injectors are to be installed, (Refer to 14 FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION).

2. Clean out fuel injector machined bores in intake manifold.

3. Apply a small amount of engine oil to each fuel injector o-ring. This will help in fuel rail installation.

4. Position fuel rail/fuel injector assembly to machined injector openings in cylinder head.

5. Guide each injector into cylinder head. Be careful not to tear injector o-rings.

6. Push right side of fuel rail down until fuel injectors have bottomed on cylinder head shoulder. Push left fuel rail down until injectors have bottomed on cylinder head shoulder.

7. Install 4 fuel rail mounting bolts and tighten. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - SPECIFICATIONS)

8. Install 6 ignition coils. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - INSTALLATION)

9. Connect electrical connectors to throttle body.

10. Connect electrical connectors at all fuel injectors.

To install connector, refer to. Push connector onto injector (1) and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging on connector.

11. Connect necessary vacuum lines to throttle body.

12. Install air resonator mounting bracket near front of throttle body (2 bolts).

13. Connect fuel line latch clip and fuel line to fuel rail. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK

CONNECT FITTING - STANDARD PROCEDURE)

14. Install air box to throttle body.

15. Install air duct to air box.

16. Connect battery cable to battery.

17. Start engine and check for leaks.

14 - 28 FUEL DELIVERY - GAS DR/DH

5.7L V-8

1. If fuel injectors are to be installed, (Refer to 14 FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION).

2. Clean out fuel injector machined bores in intake manifold.

3. Apply a small amount of engine oil to each fuel injector o-ring. This will help in fuel rail installation.

4. Position fuel rail/fuel injector assembly to machined injector openings in intake manifold.

5. Guide each injector into intake manifold. Be careful not to tear injector o-rings.

6. Push right side of fuel rail down until fuel injectors have bottomed on shoulders. Push left fuel rail down until injectors have bottomed on shoulders.

7. Install 4 fuel rail holdown clamps and 4 mounting bolts. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - SPECIFICATIONS)

8. Position spark plug cable tray and cable assembly to intake manifold. Snap 4 cable tray retaining clips into intake manifold.

9. Install all cables to spark plugs and ignition coils.

10. Connect electrical connector to throttle body.

11. Install electrical connectors to all 8 ignition coils.

(Refer to 8 - ELECTRICAL/IGNITION CONTROL/IGNITION COIL - INSTALLATION)

12. Connect electrical connector to throttle body.

13. Connect electrical connectors at all fuel injectors. To install connector, refer to. Push connector onto injector (1)

and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging on connector.

14. Connect fuel line latch clip and fuel line to fuel rail. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK

CONNECT FITTING - STANDARD PROCEDURE)

15. Install air resonator to throttle body (2 bolts).

16. Install flexible air duct to air box.

17. Connect battery cable to battery.

18. Start engine and check for leaks.

DR/DH FUEL DELIVERY - GAS 14 - 29

4.7L V-8

1. If fuel injectors are to be installed, (Refer to 14 FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION).

2. Clean out fuel injector machined bores in intake manifold.

3. Apply a small amount of engine oil to each fuel injector o-ring. This will help in fuel rail installation.

4. Position fuel rail/fuel injector assembly to machined injector openings in cylinder head.

5. Guide each injector into cylinder head. Be careful not to tear injector o-rings.

6. Push right side of fuel rail down until fuel injectors have bottomed on cylinder head shoulder. Push left fuel rail down until injectors have bottomed on cylinder head shoulder.

7. Install 4 fuel rail mounting bolts and tighten. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - SPECIFICATIONS)

8. Install 8 ignition coils. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - INSTALLATION)

9. Connect electrical connectors to throttle body.

10. Connect electrical connectors at all fuel injectors.

To install connector, refer to. Push connector onto injector (1) and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging on connector.

11. Connect necessary vacuum lines to throttle body.

12. Install air resonator mounting bracket near front of throttle body (2 bolts).

13. Connect fuel line latch clip and fuel line to fuel rail. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK

CONNECT FITTING - STANDARD PROCEDURE)

14. Install air box to throttle body.

15. Install air duct to air box.

16. Connect battery cable to battery.

17. Start engine and check for leaks.

8.3L - SRT-10

1. Install the fuel injectors to the fuel rail.

2. Install fuel rail under throttle body.

3. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.

4. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 12 N·m (105 in. lbs.).

5. Attach electrical connectors to fuel injectors.

6. Connect the electrical connector to the MAP sensor and Coolant Temperature sensor.

7. Connect the electrical connector to the TPS and Idle Air Control.

8. Install the wiring harness to the wiring clips under the throttle body.

9. Connect fuel supply tube to fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery section

10. Install the negative battery cable.

11. Install the air cleaner assembly, refer to the Engine/Air Intake System/Air Cleaner Housing for more information.

12. Use the DRBIIIT scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.

14 - 30 FUEL DELIVERY - GAS DR/DH

TANK - FUEL

DESCRIPTION

The fuel tank is constructed of a plastic material. Its main functions are for fuel storage and for placement of the fuel pump module, and (if equipped) certain 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 connections.

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) or NVLD Pump, 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 a diagnostic scan tool to activate the fuel pump relay. 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 con-

nection. Refer to diagnostic 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 application). 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 following 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 and disconnect rubber fuel fill hose at tank fitting. Using an approved gas holding tank, drain fuel tank through this fitting.

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