2002 DODGE RAM washer fluid

UNDERHOOD LAMP - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
2 M1 20PK FUSED B(+)
WASHER FLUID LEVEL SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 G29 18BK/WT WASHER FLUID SWITCH SENSE
2 Z1 18BK GROUND
WATER IN FUEL SENSOR (DIESEL)-2WAY
CAV CIRCUIT FUNCTION
A K104 18BK/LB SENSOR GROUND
B K1 18DG/RD WATER IN FUEL SENSOR SIGNAL
WIPER MOTOR-4WAY
CAV CIRCUIT FUNCTION
1 V4 16RD/YL WIPER SWITCH HIGH SPEED OUTPUT
2 V5 16DG WIPER PARK SWITCH SENSE
3 V6 16DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
4 V3 16BR/WT LOW SPEED WIPER SWITCH OUTPUT
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 81

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Right Park/Turn Signal Lamp BK At Lamp N/S
Right Power Mirror BK In Door N/S
Right Rear Fender Lamp BK On Fender 27
Right Rear Speaker BK Bottom of Right B Pillar 23
Right Remote Radio Switch Steering Wheel N/S
Right Speed Control Switch Steering Wheel N/S
Right Tail/Stop Turn Signal
LampBK At Rear Bumper 27
Right Tweeter (Premium) Right A Pillar N/S
Right Visor/Vanity Lamp BK Right A-Pillar N/S
Seat Belt Switch BK Above Left Rear Speaker 23
Seat Heat Interface Module BK Under Seat N/S
Tailgate Lamp On Tailgate 27
Throttle Position Sensor
(Gas)Throttle Body 7, 12
Trailer Tow Connector BK On Trailer Hitch 27
Transmission Range Sensor BK Left side of Transmission N/S
Transmission Solenoid
AssemblyBK Side of Transmission 16
Under Hood Lamp BK Underside of Hood 20
Vehicle Speed Control Servo BK Below Battery 21
Washer Fluid Level Switch BK At Reservoir 21
Water In Fuel Sensor (Diesel) BK Bottom of Fuel Filter/Water Separator 13
Windshield Washer Pump BK Bottom of Washer Fluid Reservior 21
Wiper Motor BK Center Rear Engine Compartment 18
GROUNDS
GROUND
NUMBERLOCATION FIG.
G100 Left Fender Side Shield 21
G101 Left Fender Side Shield 21
G102 Left Fender Side Shield (RWAL Ground) N/S
G103 Near T/O for Wiper Motor 18
G105 Front of Engine (Engine Ground) 7, 8, 12
G107 (Diesel) Left Rear of Engine 13
G113 (Diesel) Primary Battery Engine Ground N/S
G114 Battery Engine Ground N/S
G115 (Diesel) Primary Battery Body Ground N/S
G116 Battery Frame Ground N/S
G117 (Diesel) Auxilary Battery Engine Ground N/S
G118 (Diesel) Primary Frame Ground N/S
G120 (Diesel) Auxilary Battery Body Ground N/S
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONBR/BE
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

(3) Lower engine into compartment and align
engine with transmission:
²Manual Transmission: Align clutch disc assem-
bly (if disturbed). Install transmission input shaft
into clutch disc while mating engine and transmis-
sion surfaces. Install two transmission to engine
block mounting bolts finger tight.
²Automatic Transmission: Mate engine and trans-
mission and install two transmission to engine block
mounting bolts finger tight.
(4) Lower engine assembly until engine mount
through bolts rest in mount perches.
(5) Install remaining transmission to engine block
mounting bolts and tighten.
(6) Tighten engine mount through bolts.
(7) Install drive plate to torque converter bolts.
(Automatic transmission models)
(8) Install the dust shield and transmission cover.
(9) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(10) Install exhaust pipe to manifold.
(11) Install the transmission cooler line brackets to
the oil pan.
(12) Install the drain plug and tighten to 34 N´m
(25 ft. lbs.) torque.
(13) Lower the vehicle.
(14) Remove engine lifting fixture.
(15) On Manual Transmission vehicles, install the
shift lever (Refer to 21 - TRANSMISSION/TRANS-
AXLE/MANUAL/SHIFT COVER - INSTALLATION).
(16) Connect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(17) Connect the power steering hoses, if equipped.
(18) Connect the heater hoses.
(19) Install the distributor cap and wiring.
(20) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
(21) Using a new gasket, install throttle body
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE BODY - INSTALLATION).
(22) Connect the throttle linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - INSTALLATION).
(23) Install the air cleaner resonator and duct
work..
(24) Install the generator and wire connections
(Refer to 8 - ELECTRICAL/CHARGING/GENERA-
TOR - INSTALLATION).
(25) Install a/c compressor and lines (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - INSTALLATION).(26) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(27) Install upper radiator support crossmember.
(28) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(29) Connect the radiator lower hose.
(30) Connect the transmission oil cooler lines to
the radiator.
(31) Install the fan shroud.
(32) Install the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(33) Connect the radiator upper hose.
(34) Install the washer bottle.
(35) Install the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
INSTALLATION).
(36) Connect the transmission cooler lines.
(37) If equipped, install the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - INSTALLATION).
(38) Evacuate and charge the air conditioning sys-
tem, if equipped (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE).
(39) Add engine oil to crankcase (Refer to LUBRI-
CATION & MAINTENANCE/FLUID TYPES - SPEC-
IFICATIONS).
(40) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(41) Connect battery negative cable.
(42) Start engine and inspect for leaks.
(43) Road test vehicle.
SPECIFICATIONS
5.9L ENGINE
ENGINE SPECIFICATIONS
DESCRIPTION SPECIFICATION
GENERAL SPECIFICATIONS
Engine Type 90É V-8 OHV
Bore and Stroke 101.6 x 90.9 mm
(4.00 x 3.58 in.)
Displacement 5.9L (360 c.i.)
Compression Ratio 9.1:1
Firing Order 1±8±4±3±6±5±7±2
Lubrication Pressure Feed ± Full
Flow
BR/BEENGINE 5.9L 9 - 13
ENGINE 5.9L (Continued)

(1) Perform the Fuel Pressure Release Procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(7) Be sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N´m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil. (Refer to LUBRICATION &
MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery.
(16) Start the engine and check for any leaks.
REMOVAL
(1) Remove the battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Discharge the air conditioning system, if
equipped (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(4) Remove the upper crossmember.
(5) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
(6) Remove the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV-
AL).
(7) Remove the A/C compressor with the lines
attached (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C COMPRESSOR -
REMOVAL). Set aside.
(8) If equipped, remove the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - REMOVAL).(9) Remove the washer fluid reservoir bottle (Refer
to 8 - ELECTRICAL/WIPERS/WASHERS -
REMOVAL AND INSTALLATION).
(10) Disconnect the top radiator hose.
(11) Remove the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - REMOVAL).
(12) Remove the fan shroud.
(13) Disconnect the lower radiator hose.
(14) Disconnect the transmission cooler lines.
(15) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(16) Remove the generator with the wire connec-
tions (Refer to 8 - ELECTRICAL/CHARGING/GEN-
ERATOR - REMOVAL).
(17) Remove the air cleaner.
(18) Disconnect the throttle linkage.
(19) Remove throttle body (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE BODY -
REMOVAL).
(20) Remove the upper intake manifold (Refer to 9
- ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(21) Remove the coil assemblies with the ignition
cables.
(22) Disconnect the heater hoses.
(23) Disconnect the power steering hoses, if
equipped.
(24) Perform the Fuel System Pressure release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE). Disconnect
the fuel line (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(25) On Manual Transmission vehicles, remove the
shift lever.
(26) Raise and support the vehicle on a hoist.
(27) Remove the drain plug and drain the engine
oil.
(28) Loosen front engine mount thru-bolt nuts.
(29) Remove the transmission cooler line brackets
from oil pan.
(30) Disconnect exhaust pipe at manifold.
(31) Disconnect the starter wires. Remove starter
motor (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - REMOVAL).
(32) Remove transmission.
(33) Lower vehicle.
CAUTION: DO NOT lift the engine by the intake
manifold.
(34) Install an engine lifting fixture.
(35) Remove engine from vehicle and install
engine assembly on a repair stand.
BR/BEENGINE 8.0L 9 - 67
ENGINE 8.0L (Continued)

INSTALLATION
(1) Remove engine from the repair stand and posi-
tion in the engine compartment. Position the thru-
bolt into the support cushion brackets.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4) Install Transmission.
(5) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(6) Install exhaust pipe to manifold.
(7) Install the transmission cooler line brackets
from oil pan.
(8) Tighten the Front mount thru-bolts and nuts to
102N´m (75 ft. lbs.).
(9) Install the drain plug and tighten to 34 N´m
(25 ft. lbs.) torque.
(10) Prime oil pump by squirting oil in the oil fil-
ter mounting hole and filling the J-trap of the front
timing cover. When oil is running out, install oil filter
that has been filled with oil.
(11) Lower the vehicle.
(12) Remove engine lifting fixture.
(13) On Manual Transmission vehicles, install the
shift lever.
(14) Connect the fuel lines (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE).
(15) Connect the heater hoses.
(16) Install the upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
(17) Install the coil assemblies with the ignition
cables.
(18) Using a new gasket, install throttle body
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE BODY - INSTALLATION).
(19) Connect the throttle linkage.
(20) Install the air cleaner box.
(21) Install the generator and wire connections
(Refer to 8 - ELECTRICAL/CHARGING/GENERA-
TOR - INSTALLATION).
(22) Install the upper crossmember.
(23) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(24) Connect the lower radiator hose.
(25) Install the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
INSTALLATION).
(26) Connect the transmission cooler lines.
(27) Connect the power steering hoses, if equipped.
(28) Install the fan shroud.
(29) Install the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(30) Connect the top radiator hose.(31) Install the washer fluid reservoir bottle (Refer
to 8 - ELECTRICAL/WIPERS/WASHERS - INSTAL-
LATION).
(32) If equipped, install the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - INSTALLATION).
(33) Install the A/C compressor with the lines
attached (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C COMPRESSOR -
INSTALLATION).
(34) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(35) Evacuate (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE) and charge the air conditioning system, if
equipped (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(36) Add coolant to the cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(37) Install the battery.
(38) Warm engine and adjust as required.
(39) Road test vehicle.
SPECIFICATIONS
8.OL ENGINE
DESCRIPTION SPECIFICATION
CAMSHAFT
Bearing Diameter
No. 1 53.16 ± 53.19 mm
(2.093 ± 2.094 in.)
No. 2 52.76 ± 52.78 mm
(2.077 ± 2.078 in.)
No. 3 52.35 ± 52.37 mm
No. 4 51.94 ± 51.97 mm
(2.045 ± 2.046 in.)
No. 5 51.54 ± 51.56 mm
(2.029 ± 2.030 in.)
No. 6 48.74 ± 48.77 mm
(1.919 ± 1.920 in.)
Bearing Journal Diameter
No. 1 53.11 ± 53.14 mm
(2.091 ± 2.092 in.)
No. 2 52.69 ± 52.72 mm
9 - 68 ENGINE 8.0LBR/BE
ENGINE 8.0L (Continued)

(11) Install the cylinder head cover and reusable
gasket (Fig. 85) (Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - INSTALLA-
TION).
(12) Install gear housing cover (Refer to 9 -
ENGINE/VALVE TIMING/GEAR HOUSING COVER
- INSTALLATION).
(13) Install the crankshaft damper (Fig. 83) (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(14) Install the fan support/hub assembly (Fig. 82)
and tighten bolts to 24 N´m (18 ft. lbs.) torque.
(15) Install the crankcase breather housing (Refer
to 9 - ENGINE - INSTALLATION).
(16) Install the charge air cooler (with a/c con-
denser and auxiliary transmission oil cooler, if
equipped) and tighten the mounting bolts to 2 N´m
(17 in. lbs.) torque.
(17) Connect charge air cooler inlet and outlet
pipes. Tighten clamps to 10 N´m (100 in. lbs.) torque.
(18) Install the radiator upper support panel.
(19) Close radiator petcock and lower the radiator
into the engine compartment. Tighten the mounting
bolts to 11 N´m (95 in. lbs.) torque.
(20) Raise vehicle on hoist.
(21) Connect radiator lower hose and install
clamp.
(22) Connect transmission auxiliary oil cooler lines
(if equipped).
(23) Lower vehicle.
(24) Install the fan shroud and tighten the mount-
ing screws to 6 N´m (50 in. lbs.) torque.
(25) Install the viscous fan/drive assembly (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(26) Install the coolant recovery and windshield
washer fluid reservoirs to the fan shroud.
(27) Connect the coolant recovery hose to the radi-
ator filler neck.
(28) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(29) Install the front bumper assembly (Refer to 13
- FRAMES & BUMPERS/BUMPERS/FRONT
BUMPER - INSTALLATION).
(30) Add engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(31) Charge A/C system with refrigerant (if A/C
equipped) (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(32) Connect the battery negative cables.
(33) Start engine and check for engine oil and cool-
ant leaks.CONNECTING ROD BEARINGS
STANDARD PROCEDUREÐCONNECTING ROD
BEARING AND CRANKSHAFT JOURNAL
CLEARANCE
Measure the connecting rod bore with the bearings
installed and the bolts tightened to 100 N´m (73 ft.
lbs.) torque.
Record the smaller diameter.
Measure the diameter of the rod journal at the
location shown (Fig. 99). Calculate the average diam-
eter for each side of the journal.
The clearance is the difference between the con-
necting rod bore (smallest diameter) and the average
diameter for each side of the crankshaft journal.
Fig. 99 Connecting Rod Journal Diameter Limits
CONNECTING ROD JOURNAL DIAMETER
LIMITS CHART
DESCRIPTION MEASUREMENT
CRANKSHAFT ROD JOURNAL
DIAMETERMINIMUM 68.962 mm
(2.715 in.)
MAXIMUM 69.013 mm
(2.717 in.)
OUT-OF-ROUND MAXIMUM 0.050 mm (0.002 in.)
TAPER MAXIMUM 0.013 mm
(0.0005 in.)
BEARING CLEARANCE MAXIMUM 0.089 mm
(0.0035 in.)
9 - 158 ENGINE 5.9L DIESELBR/BE
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

(3) Always check the condition of the used oil. This
can give you an indication of engine problems that
might exist.
²Thin, black oil indicates fuel dilution.
²Milky discoloration indicates coolant dilution.
(4) Clean the area around the oil filter head.
Remove the filter (Refer to 9 - ENGINE/LUBRICA-
TION/OIL FILTER - REMOVAL).
(5) Install new oil filter (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION).
(6) Clean the drain plug and the sealing surface of
the pan. Check the condition of the threads and seal-
ing surface on the oil pan and drain plug.
(7) Install the drain plug. Tighten the plug to 50
N´m (37 ft. lbs.) torque.
(8) Use only High-Quality Multi-Viscosity lubricat-
ing oil in the Cummins Turbo Diesel engine. Choose
the correct oil for the operating conditions (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(9) Fill the engine with the correct grade of new oil
(Refer to LUBRICATION & MAINTENANCE/FLUID
CAPACITIES - SPECIFICATIONS).
(10) Start the engine and operate it at idle for sev-
eral minutes. Check for leaks at the filter and drain
plug.
(11) Stop engine. Wait several minutes to allow the
oil to drain back to the pan and check the level
again.
USED ENGINE OIL DISPOSAL Care should be
exercised when disposing of used engine oil after
it has been drained from a vehicle's engine.
OIL COOLER & LINES
CLEANING AND INSPECTION
Clean the sealing surfaces.
Apply 483 kPa (70 psi) air pressure to the element
to check for leaks. If the element leaks, replace the
element.
OIL FILTER
REMOVAL
(1) Clean the area around the oil filter head.
Remove the filter using a 90-95 mm filter wrench.
(2) Clean the gasket surface of the filter head. The
filter canister O-Ring seal can stick on the filter
head. Make sure it is removed.
INSTALLATION
(1) Fill the oil filter element with clean oil before
installation. Use the same type oil that will be used
in the engine.
(2) Apply a light film of lubricating oil to the seal-
ing surface before installing the filter.
CAUTION: Mechanical over-tightening may distort
the threads or damage the filter element seal.
(3) Install the filter until it contacts the sealing
surface of the oil filter adapter. Tighten filter an
additional ó turn.
OIL PAN
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Remove transmission and transfer case (if
equipped).
(4) Remove flywheel.
(5) Disconnect starter cables from starter motor.
(6) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
and transmission adapter plate assembly.
WARNING: HOT OIL CAN CAUSE PERSONAL
INJURY.
(7) Drain the engine oil (Refer to 9 - ENGINE/LU-
BRICATION/OIL - STANDARD PROCEDURE).
(8) Install the oil pan drain plug with a new seal-
ing washer and tighten to 60 N´m (44 ft. lbs.) torque.
(9) Remove oil pan bolts, break the pan to block
seal, and lower pan slightly and remove oil suction
tube fasteners.
(10) Remove oil pan and suction tube (Fig. 151).
CLEANING
Remove all gasket material from the oil pan and
cylinder block sealing surfaces. Extra effort may be
required around T-joint areas. Clean oil pan and
flush suction tube with a suitable solvent.
INSPECTION
Inspect the oil pan, suction tube, and tube braces
for cracks and damage. Replace any defective compo-
nent. Inspect the oil drain plug and drain hole
threads. Inspect the oil pan sealing surface for
straightness. Repair any minor imperfections with a
ball-peen hammer. Do not attempt to repair an oil
pan by welding.
BR/BEENGINE 5.9L DIESEL 9 - 179
OIL (Continued)

Testing Fuel Transfer Pump
(1) Leave vacuum pump attached to fuel supply
line (Fig. 5).
(2) Disconnect rubber fuel hose from fitting at out-
let side of fuel transfer pump (Fig. 5). To plug / seal
system, install 3/8º rubber cap to this fitting (Fig. 5).
(3) Perform vacuum test. Be careful not to allow
liquid fuel to get into your hand-operated vacuum
pump.
(4) Vacuum leak ? Check/repair all transfer pump
fittings and sealing washers for leaks. Check/repair
rubber hose and clamps at sides of transfer pump for
leaks. Perform another vacuum test. If leak still
present, replace fuel transfer pump.
(5) Vacuum holds ? Proceed.
Testing Fuel Filter / Water Separator
(1) Leave vacuum pump attached to fuel supply
line (Fig. 4).
(2) Disconnect rubber fuel hose located between
VP-44 pump and fuel filter/water separator (Fig. 6).
To allow easier hose removal, remove test port fitting
and fuel inlet line at VP-44 pump (Fig. 6). To plug /
seal system, install 3/8º rubber cap to this outline
line (Fig. 7).
(3) Reconnect rubber fuel hose to fitting at outlet
side of fuel transfer pump (Fig. 5).
(4) Perform vacuum test. Be careful not to allow
liquid fuel to get into hand-operated vacuum pump.(5) Vacuum leak ? Check/repair all fittings and
sealing washers for leaks. Check/repair rubber hose
and clamps for leaks. Check fuel heater and water-
in-fuel sensor o-rings for leaks. Check filter canister
seal at top of canister for leaks. Repair as necessary.
(6) Vacuum holds ? Proceed.
Testing VP-44 Pump and Fuel Return / Drain System Within
Cylinder Head
(1) Leave vacuum pump attached to fuel supply
line (Fig. 4).
(2) Position rubber hose and 2 clamps to VP-44
drain line. Install test port fitting and fuel drain line
to VP-44 pump. Tighten test port fitting to 24 N´m
(18 ft. lbs. or 212 in. lbs.) torque. Position 2 hose
clamps to rubber hose.
(3) Loosen, but do not remove, fuel line support
bracket bolt (Fig. 8).
(4) Disconnect and separate fuel drain line at top
of ªTº fitting (Fig. 8). To plug / seal system, install
3/8º rubber cap to this disconnected line (Fig. 8).
(5) Perform vacuum test. Be careful not to allow
liquid fuel to get into your hand-operated vacuum
pump.
(6) Vacuum leak ?
(a) Check return line banjo bolt and sealing
washers at rear of cylinder head for leaks. Repair
as necessary.
Fig. 4 VACUUM PUMP INSTALLED TO FUEL LINE
1 - FUEL SUPPLY LINE
2 - FUEL TRANSFER PUMP
3 - FUEL RETURN LINE
4 - RUBBER CAP
5 - FLUID CONTAINER
6 - HAND-OPERATED PUMP
Fig. 5 FUEL HOSE AT TRANSFER PUMP
1 - HAND-OPERATED PUMP
2 - RUBBER CAP TO FUEL TRANSFER PUMP OUTLET FITTING
3 - DISCONNECTED FUEL OUTLET HOSE
4 - FUEL TRANSFER PUMP
5 - TRANSFER PUMP INLET FITTING
14 - 58 FUEL DELIVERY - DIESELBR/BE
FUEL DELIVERY - DIESEL (Continued)