1998 DODGE RAM 1500 Electrical

OPERATION
Fuel Pressure Regulator Operation:The pres-
sure regulator is a mechanical device that is not con-
trolled 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 injectors. It contains a diaphragm, calibrated
springs and a fuel return valve. The internal fuel fil-
ter (Fig. 2) is also part of the assembly.
Fuel is supplied to the filter/regulator by the elec-
tric fuel pump through an opening tube at the bot-
tom of filter/regulator (Fig. 2).
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.
Both fuel filters (at bottom of fuel pump module
and within fuel pressure regulator) are designed for
extended service. They do not require normal sched-
uled maintenance. Filters should only be replaced if
a diagnostic procedure indicates to do so.
FUEL LEVEL SENDING UNIT /
SENSOR
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 vari-
able 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 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 acti-
vated if the fuel level in the tank is more than
approximately 85 percent of its rated capacity.
Fig. 2 SIDE VIEW - FILTER/REGULATOR
1 - INTERNAL FUEL FILTER
2 - FUEL FLOW TO FUEL INJECTORS
3 - FUEL FILTER/FUEL PRESSURE REGULATOR
4 - EXCESS FUEL BACK TO TANK
5 - FUEL INLET
6 - RUBBER GROMMET
7 - TOP OF PUMP MODULE
14 - 6 FUEL DELIVERY - GASDR
FUEL FILTER/PRESSURE REGULATOR (Continued)

REMOVAL
The fuel level sending unit (fuel level sensor) and
float assembly is located on the side of the fuel pump
module (Fig. 3).
(1) Remove fuel pump module from fuel tank.
Refer to Fuel Pump Module Removal/Installation.
(2) To remove sending unit from pump module, lift
on plastic locking tab (Fig. 4) while sliding sending
unit tracks.
(3) Disconnect 4±wire electrical connector (Fig. 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.
INSTALLATION
(1) Connect necessary wiring into electrical con-
nectors. 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.
FUEL LINES
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 COMPO-
NENTS, FUEL SYSTEM PRESSURE MUST BE
RELEASED. REFER TO THE FUEL SYSTEM PRES-
SURE 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 contami-
nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, only those marked EFM/EFI
may be used.
If equipped:The hose clamps used to secure rub-
ber hoses on fuel injected vehicles are of a special
rolled edge construction. This construction is used to
prevent the edge of the clamp from cutting into the
hose. Only these rolled edge type clamps may be
used in this system. All other types of clamps may
cut into the hoses and cause high-pressure fuel leaks.
Use new original equipment type hose clamps.
Fig. 3 LOCATION - FUEL GAUGE SENDING UNIT
1 - FUEL FILTER / FUEL PRESSURE REGULATOR
2 - FUEL PUMP MODULE ASSEMBLY
3 - 4-WAY ELEC. CONNECT.
4 - FLOAT ARM
5 - ELEC. FUEL PUMP
6 - INLET FILTER
7 - FUEL GAUGE SENDING UNIT
8 - GASKET (SEAL)
Fig. 4 FUEL GAUGE SENDING UNIT - R/I
1 - SENDING UNIT
2 - LOCK TAB
3 - TRACKS
4 - NOTCH
DRFUEL DELIVERY - GAS 14 - 7
FUEL LEVEL SENDING UNIT / SENSOR (Continued)

(d) Insert special fuel line removal tool (Snap-On
number FIH 9055-1 or equivalent) into fuel line
(Fig. 14). Use tool to release locking fingers in end
of line.
(e) With special tool still inserted, pull fuel line
from fuel rail.
(f) After disconnection, locking fingers will
remain within quick-connect fitting at end of fuel
line.
(10) Disconnect quick-connect fitting from fuel sys-
tem component being serviced.
CONNECTING
(1) Inspect quick-connect fitting body and fuel sys-
tem 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 indi-
cates fuel line is not properly installed to fuel
rail (or other fuel line). Recheck fuel line con-
nection.
(8) Connect negative cable to battery.
(9) Start engine and check for leaks.
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, service-
able component.
FUEL PUMP MODULE
DESCRIPTION
The fuel pump module assembly is located on the
top of the fuel tank (Fig. 1). The complete assembly
contains the following components:
²A combination fuel filter/fuel pressure regulator
²A separate fuel pick-up, or inlet filter
²An electric fuel pump
²A lockring to retain pump module to tank
²A soft gasket between tank flange and module
²A fuel gauge sending unit (fuel level sensor)
²Fuel line connection
The fuel gauge sending unit may be serviced sepa-
rately. 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.
Fig. 14 FUEL LINE DISCONNECTION USING
SPECIAL TOOL
1 - SPECIAL FUEL LINE TOOL
2 - FUEL LINE
3 - FUEL RAIL
DRFUEL DELIVERY - GAS 14 - 11
QUICK CONNECT FITTING (Continued)

REMOVAL
3.7L V-6
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT 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 (Fig. 18). 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 6 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 6 ignition coils. Refer to Ignition Coil
Removal/Installation.
(12) Remove 4 fuel rail mounting bolts (Fig. 18).
(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.
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
DRFUEL DELIVERY - GAS 14 - 13
FUEL RAIL (Continued)

4.7L 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.
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.
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.
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
14 - 14 FUEL DELIVERY - GASDR
FUEL RAIL (Continued)

(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 from
cable 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.
INSTALLATION
3.7L V-6
(1) If fuel injectors are to be installed, refer to Fuel
Injector Removal/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 care-
ful not to tear injector o-rings.
(6) Pushrightside of fuel rail down until fuel
injectors have bottomed on cylinder head shoulder.Pushleftfuel rail down until injectors have bot-
tomed on cylinder head shoulder.
Fig. 20 5.7L FUEL RAIL
1 - FUEL RAIL
2 - MOUNTING BOLT
3 - HOLDOWN CLAMPS
4 - CONNECTOR TUBE
Fig. 21 5.7L SPARK PLUG CABLE ROUTING TRAY
1 - SPARK PLUG CABLES
2 - RETAINING CLIP
3 - SPARK PLUG CABLE ROUTING TRAY
DRFUEL DELIVERY - GAS 14 - 15
FUEL RAIL (Continued)

(7) Install 4 fuel rail mounting bolts and tighten.
Refer to torque specifications.
(8) Install 6 ignition coils. Refer to Ignition Coil
Removal/Installation.
(9) Connect electrical connectors to throttle body.
(10) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 17). 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.
(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 Quick-Connect Fittings.
(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.
4.7L V-8
(1) If fuel injectors are to be installed, refer to Fuel
Injector Removal/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 care-
ful not to tear injector o-rings.
(6) Pushrightside of fuel rail down until fuel
injectors have bottomed on cylinder head shoulder.
Pushleftfuel rail down until injectors have bot-
tomed on cylinder head shoulder.
(7) Install 4 fuel rail mounting bolts and tighten.
Refer to torque specifications.
(8) Install 8 ignition coils. Refer to Ignition Coil
Removal/Installation.
(9) Connect electrical connectors to throttle body.
(10) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 17). 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.
(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 Quick-Connect Fittings.
(14) Install air box to throttle body.
Fig. 22 5.7L SPARK PLUG CABLE ROUTING
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)
14 - 16 FUEL DELIVERY - GASDR
FUEL RAIL (Continued)

(15) Install air duct to air box.
(16) Connect battery cable to battery.
(17) Start engine and check for leaks.
5.7L V-8
(1) If fuel injectors are to be installed, refer to Fuel
Injector Removal/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) Pushrightside of fuel rail down until fuel
injectors have bottomed on shoulders. Pushleftfuel
rail down until injectors have bottomed on shoulders.
(7) Install 4 fuel rail holdown clamps and 4 mount-
ing bolts. Refer to Torque Specifications.
(8) Position spark plug cable tray and cable assem-
bly 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 Ignition Coil Removal/Installation.
(12) Connect electrical connector to throttle body.
(13) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 17). 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.
(14) Connect fuel line latch clip and fuel line to
fuel rail. Refer to Quick-Connect Fittings.
(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.
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. 23) and disconnect rubber
fuel fill hose at tank fitting. Using an approved gas
holding tank, drain fuel tank through this fitting.
DRFUEL DELIVERY - GAS 14 - 17
FUEL RAIL (Continued)