2003 DODGE RAM Fuel system

SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Adjusting StrapÐBolt 23 Ð 200
Air Heater Power SupplyÐ
Nuts14 Ð 124
Air Inlet HousingÐBolts 24 18 Ð
Cab Heater Supply/Return
LineÐNuts24 18 Ð
Exhaust ClampÐNuts 48 35 Ð
Exhaust Manifold to Cylinder
HeadÐBolts
(Diesel Engine) 43 32 Ð
Exhaust Manifold to Cylinder
HeadÐBolts
(5.9L) 31 23 Ð
Exhaust Manifold to Cylinder
HeadÐBolts
(8.0L) 22 Ð 195
Exhaust Pipe to ManifoldÐ
Bolts31 23 Ð
Generator MountingÐBolts 41 30 Ð
Charge Air Cooler
MountingÐBolts2Ð17
Charge Air Cooler DuctÐ
Nuts11 Ð 9 5
Heat ShieldÐNuts and Bolts 11 Ð 95
Turbocharger flange studs 24 18 Ð
Turbocharger MountingÐ
Nuts43 32 Ð
Turbocharger Oil Drain
TubeÐBolts24 18 Ð
Turbocharger Oil Supply
LineÐFitting24 18 Ð
Turbocharger V-Band
ClampÐNut9Ð75
Turbocharger Oil Supply
fitting (at Turbocharger)36 27 Ð
Turbocharger Oil Supply
fitting (at lube filter head)24 18 Ð
Turbocharger Drain Hose
Clamps8Ð71
SPECIAL TOOLS
CATALYTIC CONVERTER
DESCRIPTION - CATALYTIC CONVERTER
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
CAUTION: DO NOT remove spark plug wires from
plugs or by any other means short out cylinders.
Failure of the catalytic converter can occur due to a
temperature increase caused by unburned fuel
passing through the converter.
The stainless steel catalytic converter body is
designed to last the life of the vehicle. Excessive heat
can result in bulging or other distortion, but exces-
sive heat will not be the fault of the converter. If
unburned fuel enters the converter, overheating may
occur. If a converter is heat-damaged, correct the
cause of the damage at the same time the converter
is replaced. Also, inspect all other components of the
exhaust system for heat damage.
Unleaded gasoline must be used to avoid con-
taminating the catalyst core.
50 State emission vehicles incorporate two mini
catalytic converters located after the exhaust mani-
folds and before the inline catalytic converter.
OPERATION
The catalytic converter captures and burns any
unburned fuel mixture exiting the combustion cham-
bers during the exhaust stroke of the engine. This
process aids in reducing emissions output.
TURBOCHARGER TESTER 9022
11 - 4 EXHAUST SYSTEMDR
EXHAUST SYSTEM (Continued)

REMOVAL
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove the bolts from the crossover pipe to the
catalytic converter connection.
(4) Disconnect oxygen sensor wiring.
(5) Loosen the nuts from the clamp that hold the
catalytic converter to the exhaust pipe flange connec-
tion.
NOTE: Do not remove nut from T-Bolt. Only remove
nut far enough, so that the T end can be removed
from the clamp.
(6) Remove the T bolt end of the fastener, from the
clamp.
(7) Spread the clamp, and remove the catalytic
converter from the vehicle.
(8) Discard the clamp.
NOTE: The catalytic converter to exhaust manifold
clamp is not reusable. Always use a new clamp
when reinstalling the catalytic converter.
REMOVAL
(1) Raise and support vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove clamps and nuts.
(4) Remove the catalytic converter.
INSPECTION
Look at the stainless steel body of the converter,
inspect for bulging or other distortion that could be a
result of overheating. If the converter has a heat
shield attached make sure it is not bent or loose.
If you suspect internal damage to the catalyst, tap-
ping the bottom of the catalyst with a rubber mallet
may indicate a damaged core.
INSTALLATION
INSTALLATION
NOTE: The catalytic converter to exhaust manifold
clamp is not reusable. Always use a new clamp
when reinstalling the catalytic converter.(1) Position the catalytic converter onto the
exhaust pipe flange connection. Tighten the nuts to
28 N´m (250 in. lbs.) torque.
(2) Install the muffler onto the catalytic converter
until the alignment tab is inserted into the align-
ment slot.
(3) Install the exhaust clamp at the muffler and
catalytic converter connection. Tighten the clamp
nuts to 47 N´m (35 ft. lbs.) torque.
(4) Connect oxygen sensor wiring.
(5) Lower the vehicle.
(6) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
INSTALLATION
(1) Assemble converter and clamps loosely in
place.
(2) Install the exhaust pipe onto exhaust mani-
folds, tighten 31 N´m (23 ft. lbs.).
(3) Tighten all clamp nuts to 48 N´m (35 ft. lbs.)
torque.
(4) Lower the vehicle.
(5) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels. A
minimum of 25.4 mm (1.0 in.) is required between
exhaust system components and body/frame parts.
Adjust the alignment, if needed.
EXHAUST PIPE
REMOVAL
REMOVAL Ð 5.9L
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove exhaust pipe to manifold bolts, retain-
ers and nuts.
(4) Remove the clamp nuts.
(5) Remove the exhaust pipe (Fig. 1).
REMOVAL
CAUTION: When servicing or replacing exhaust
system components, disconnect the oxygen sensor
connector(s). Allowing the exhaust to hang by the
oxygen sensor wires will damage the harness
and/or sensor.
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with MopartRust
Penetrant. Allow 5 minutes for penetration.
(3) Disconnect the oxygen sensor(s).
DREXHAUST SYSTEM 11 - 5
CATALYTIC CONVERTER (Continued)

(1) Loosen clamps holding air inlet duct rubber
sleeve to the intake manifold and air inlet duct.
Remove rubber sleeve (Fig. 13).
(2) Position Special Tool 8462 onto air inlet duct
and intake manifold. Using the existing clamps
tighten to 8 N´m (72 in. lbs.).
(3) Install the 3447.5 kPa 500 psi (gray) Pressure
Transducer (part of OT-CH8520 Transducer Kit) into
Special Tool 8462.
(4) Connect the DRB IIItto the pressure trans-
ducer following the instructions supplied with the
DRB IIIt.
(5) Enter DRB IIItinto pressure reading mode
and test drive vehicle.
(6) Full laod boost pressure at rated speed will be
158 - 186 kPa (23 - 27 psi.) depending on engine hp
rating.. If pressure readings are are not within this
range inspect for the following:
²Restricted air inlet system
²Leak in the charge air cooler system (Refer to 11
- EXHAUST SYSTEM/TURBOCHARGER SYSTEM/
CHARGE AIR COOLER AND PLUMBING - DIAG-
NOSIS AND TESTING)
²Turbocharger wastegate broken or misadjusted
²Restricted/high pressure drop across charge air
cooler²Turbocharger damaged (Refer to 11 - EXHAUST
SYSTEM/TURBOCHARGER SYSTEM/TURBO-
CHARGER - INSPECTION)
TURBOCHARGER
DESCRIPTION
The turbocharger is an exhaust-driven supercharger
which increases the pressure and density of the air
entering the engine. With the increase of air entering
the engine, more fuel can be injected into the cylin-
ders, which creates more power during combustion.
The turbocharger assembly consists of four (4)
major component systems (Fig. 14) (Fig. 15) :
²Turbine section
²Compressor section
²Bearing housing
²Wastegate
OPERATION
Exhaust gas pressure and energy drive the tur-
bine, which in turn drives a centrifugal compressor
that compresses the inlet air, and forces the air into
the engine through the charge air cooler and plumb-
ing. Since heat is a by-product of this compression,
the air must pass through a charge air cooler to cool
the incoming air and maintain power and efficiency.
Increasing air flow to the engine provides:
²Improved engine performance
²Lower exhaust smoke density
Fig. 13 INTAKE MANIFOLD TO AIR INLET DUCT
RUBBER SLEEVE
1 - INTAKE MANIFOLD AIR INLET
2 - CLAMPS
3 - AIR INLET DUCT
4 - AIR INLET DUCT RUBBER SLEEVE
Fig. 14 Turbocharger Operation
1 - TURBINE SECTION
2 - EXHAUST GAS
3 - BEARING HOUSING
4 - COMPRESSOR SECTION
5 - INLET AIR
6 - COMPRESSED AIR TO ENGINE
7 - EXHAUST GAS
8 - EXHAUST GAS TO EXHAUST PIPE
DREXHAUST SYSTEM 11 - 11
TURBOCHARGER SYSTEM (Continued)

(3)Pre-lube the turbocharger.Pour 50 to 60 cc
(2 to 3 oz.) clean engine oil in the oil supply line fit-
ting. Carefully rotate the turbocharger impeller by
hand to distribute the oil thoroughly.
(4) Install and tighten the oil supply line to 24
N´m (18 ft. lbs.) torque.
(5) Position the charge air cooler inlet pipe to the
turbocharger. With the clamp in position, tighten the
clamp nut to 11 N´m (95 in. lbs.) torque.
(6) Position the air inlet hose to the turbocharger
(Fig. 18). Tighten the clamp to 11 N´m (95 in. lbs.)
torque.
(7) Raise vehicle on hoist.
(8) Connect the exhaust pipe to the turbocharger
and tighten the bolts to 34 N´m (25 ft. lbs.) torque.
(9) Lower the vehicle.
(10) Connect the battery negative cables.
(11) Start the engine to check for leaks.
CHARGE AIR COOLER AND
PLUMBING
DESCRIPTION
The charge air system (Fig. 23) consists of the
charge air cooler piping, charge air cooler and intake
air grid heater.
The charge air cooler is a heat exchanger that uses
air flow from vehicle motion to dissipate heat from
the intake air. As the turbocharger increases air
pressure, the air temperature increases. Lowering
the intake air temperature increases engine effi-
ciency and power.
OPERATION
Intake air is drawn through the air cleaner and
into the turbocharger compressor housing. Pressur-ized air from the turbocharger then flows forward
through the charge air cooler located in front of the
radiator. From the charge air cooler the air flows
back into the intake manifold.
DIAGNOSIS AND TESTING - CHARGE AIR
COOLER SYSTEM - LEAKS
Low turbocharger boost pressure and low engine
performance can be caused by leaks in the charge air
cooler or it's plumbing. Fuel staining on the exhaust
manifold can also be an indication that there are
leaks in the air system.The following procedure out-
lines how to check for leaks in the charge air cooler
system.
(1) Loosen clamp and remove air inlet hose from
turbocharger.
(2)
Insert Special Tool 9022 Adapter into the turbo-
charger inlet. Tighten tool clamp to 8 N´m (72 in. lbs.).
CAUTION: Do not apply more than 138 kPa (20 psi)
air pressure to the charge air cooler system, sever
damage to the charge air cooler system may occur.
(3) Connect a regulated air supply to air fitting on
Special Tool 9022 Adapter. Set air pressure to a Max-
imum of 138 kPa (20 psi).
(4) Using soapy water check the rubber sleeves,
charge air cooler and intake manifold for leaks.
REMOVAL
WARNING: IF THE ENGINE WAS JUST TURNED
OFF, THE AIR INTAKE SYSTEM TUBES MAY BE
HOT.
Fig. 22 Measure Turbocharger Bearing Radial
Clearance
1 - FEELER GAUGE
Fig. 23 Intake Air Circulation
1 - CHARGE AIR COOLER
2 - AIRFILTER
3 - TURBOCHARGER
DREXHAUST SYSTEM 11 - 15
TURBOCHARGER (Continued)

REAR BUMPER
REMOVAL
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
(2) Remove the license plate.
(3) Remove the bolts behind the plate.
(4) Disconnect the license plate light electrical con-
nectors.
(5) Disconnect the trailer light connector electrical
connection, if equipped.
(6) Remove the two bolts along the front upper
edge of the bumper near the frame tips.
(7)
Support the bumper with a suitable lifting device.
(8) Remove the bolts attaching the bumper support
brackets to the trailer hitch. (Fig. 5)
INSTALLATION
(1) Align the holes in the bumpers to the trailer
hitch pins and install the bumper.
(2) Install the support bracket to the hitch bolts,
loosely.
(3) Install the front upper edge to the trailer hitch
bolts and tighten to 54 N´m (40 ft. lbs.).
(4) Install the license plate reinforcement to hitch
bolts and tighten to 54 N´m (40 ft. lbs.).
(5) Tighten the left bumper bracket bolts to 54
N´m (40 ft. lbs.).
(6) Tighten the right bumper bracket bolts to 54
N´m (40 ft. lbs.).
(7) Connect the trailer light connector electrical
connection, if equipped.
(8) Connect the license plate light electrical con-
nectors.
(9) Install the license plate.
FRAME
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY FRONT
FRAME RAIL TIP REPLACEMENT
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT.
²BEFORE PROCEEDING WITH FRAME REPAIR
INVOLVING GRINDING OR WELDING, VERIFY THAT
VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN
CONTACT WITH REPAIR AREA, PERSONAL INJURY
CAN RESULT.
²DO NOT ALLOW OPEN FLAME OR HEAT AND
METAL SPATTER FROM ARC WELDING, TO CON-
TACT PLASTIC BODY PANELS. FIRE OR EXPLO-
SION CAN RESULT.
²WHEN WELDED FRAME COMPONENTS ARE
REPLACED, ENSURE COMPLETE PENETRATION
WELD IS ACHIEVED DURING INSTALLATION. IF
NOT, DANGEROUS OPERATING CONDITIONS CAN
RESULT.
²STAND CLEAR OF CABLES OR CHAINS ON
PULLING EQUIPMENT DURING FRAME STRAIGHT-
ENING OPERATIONS, PERSONAL INJURY CAN
RESULT.
²DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT SUPPORTED ON SAFETY
STANDS, PERSONAL INJURY CAN RESULT.
CAUTION: 1500 series Dodge Ram Trucks (2002 and
later) are not designed for snow plow equipment.
The front collision repair tips must not be installed
on any truck equipped with a snow plow, or even
intended to be equipped with a snow plow.
CAUTION: This procedure is designed to replace
the front frame rail tips that have been damaged in
the crush initiator zones. Prior to any cutting, the
vehicle must be mounted on the appropriate frame
repair equipment (ªframe rackº), checked with three
dimensional measuring equipment, and the neces-
sary pull corrections made. If damage remains in
the frame beyond the area covered by this service
part after the pull, the frame must be replaced in its
entirety.
Fig. 5 TRAILER HITCH
1 - HITCH
2 - HITCH BOLTS (4)
3 - BUMPER BRACKET BOLTS (4)
4 - BUMPER SUPPORT BRACKETS
13 - 4 FRAMES & BUMPERSDR

STANDARD PROCEDURE - HYDROFORM
FENDER RAIL REPAIR
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT.
²BEFORE PROCEEDING WITH FRAME REPAIR
INVOLVING GRINDING OR WELDING, VERIFY THAT
VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN
CONTACT WITH REPAIR AREA, PERSONAL INJURY
CAN RESULT.
²DO NOT ALLOW OPEN FLAME OR HEAT AND
METAL SPATTER FROM ARC WELDING, TO CON-
TACT PLASTIC BODY PANELS. FIRE OR EXPLO-
SION CAN RESULT.
²WHEN WELDED FRAME COMPONENTS ARE
REPLACED, ENSURE COMPLETE PENETRATION
WELD IS ACHIEVED DURING INSTALLATION. IF
NOT, DANGEROUS OPERATING CONDITIONS CAN
RESULT.
²STAND CLEAR OF CABLES OR CHAINS ON
PULLING EQUIPMENT DURING FRAME STRAIGHT-
ENING OPERATIONS, PERSONAL INJURY CAN
RESULT.
²DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT SUPPORTED ON SAFETY
STANDS, PERSONAL INJURY CAN RESULT.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Failure to use only pro-
duction fasteners or fasteners of equivalent hard-
ness can result in loosening or failure. Do not drill
holes in top or bottom frame rail flanges, frame rail
failure can result. When using heat to straighten
frame components do not exceed 566ÉC (1050ÉF),
metal fatigue can result.
CAUTION: This repair procedure assumes damage
to the right or left hydroform fender rail (Fig. 19).
Prior to any repairs, the vehicle must be mounted
on the appropriate frame repair equipment (ªframe
rackº), checked with three dimensional measuring
equipment, and necessary pull corrections made. If
damage exists in the hydroform fender rail, or cab
beyond the area covered by this service procedure
after dimensional corrections are made, the hydro-
form must be replaced in its entirety. Refer to 23 -
BODY/BODY STRUCTURE/WELD LOCATIONS -
SPECIFICATIONS, when replacing the entire hydro-
form.(1) Disconnect and isolate the battery negative
cable.
(2) Remove the front wheelhouse splash shield.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL-
HOUSE SPLASH SHIELD - REMOVAL)
(3) Remove the fender. (Refer to 23 - BODY/EXTE-
RIOR/FRONT FENDER - REMOVAL)
(4) Remove the A/C condenser, if required. (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/A/C CONDENSER - REMOVAL)
(5) Remove the A/C lines, if required. Refer to the
Heating and Air Conditioning section of the manual
for recommended procedures.
(6) Remove the radiator assembly. (Refer to 7 -
COOLING/ENGINE/RADIATOR - REMOVAL)
(7) Remove the air cleaner and support bracket, if
required. (Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER ELEMENT - REMOVAL)
(8) Remove the integrated power module. (Refer to
8 - ELECTRICAL/POWER DISTRIBUTION/INTE-
GRATED POWER MODULE - REMOVAL)
(9) Remove the bolts and position aside the wire
harness and grounds, if required.
(10) Remove the upper radiator crossmember.
(Refer to 23 - BODY/EXTERIOR/UPPER RADIATOR
CROSSMEMBER - REMOVAL)
(11) Remove the headlamp unit. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP UNIT - REMOVAL)
(12) Remove the front cab mount to the Front End
Sheet Metal bracket (FESM) bolt.
(13) Remove the bolts attaching the lower radiator
crossmember to the hydroform fender rail. (Fig. 19)
CAUTION: Do not use any flame or plasma cutting
equipment to cut the frame in this procedure. The
inaccurate and high temperatures achieved during
flame or plasma cutting will change the metal char-
acteristics and may weaken the frame and/or repair
location.
(14) Using a reciprocating saw or equivalent, cut
the fender rail and shotgun at a straight and square
section of the hydroform and remove.
(15) Smooth and square the cut edges.
(16) Using the damaged structure as a reference
cut the service part at the same location as the first
cut. Smooth and square the cut edges.
NOTE: The repair structure should butt up to the
remaining structure and provide the same overall
vehicle geometry.
13 - 12 FRAMES & BUMPERSDR
FRAME (Continued)

STANDARD PROCEDURE - REAR FRAME
H-SECTION REPLACEMENT
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT.
²BEFORE PROCEEDING WITH FRAME REPAIR
INVOLVING GRINDING OR WELDING, VERIFY THAT
VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN
CONTACT WITH REPAIR AREA, PERSONAL INJURY
CAN RESULT.
²DO NOT ALLOW OPEN FLAME OR HEAT AND
METAL SPATTER FROM ARC WELDING, TO CON-
TACT PLASTIC BODY PANELS. FIRE OR EXPLO-
SION CAN RESULT.
²WHEN WELDED FRAME COMPONENTS ARE
REPLACED, ENSURE COMPLETE PENETRATION
WELD IS ACHIEVED DURING INSTALLATION. IF
NOT, DANGEROUS OPERATING CONDITIONS CAN
RESULT.
²STAND CLEAR OF CABLES OR CHAINS ON
PULLING EQUIPMENT DURING FRAME STRAIGHT-
ENING OPERATIONS, PERSONAL INJURY CAN
RESULT.
²DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT SUPPORTED ON SAFETY
STANDS, PERSONAL INJURY CAN RESULT.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Failure to use only pro-
duction fasteners or fasteners of equivalent hard-
ness can result in loosening or failure. Do not drill
holes in top or bottom frame rail flanges, frame rail
failure can result. When using heat to straighten
frame components do not exceed 566ÉC (1050ÉF),
metal fatigue can result.
CAUTION: This procedure is designed to replace
the H-section/spare tire support located at the rear
of the frame assembly. Prior to any cutting, the
vehicle must be mounted on the appropriate frame
repair equipment (ªframe rackº), checked with three
dimensional measuring equipment, and the neces-
sary pull corrections made. If damage remains in
the frame beyond the area covered by this service
part after the pull, the frame must be replaced in its
entirety.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cargo box. (Refer to 23 - BODY/EX-
TERIOR/CARGO BOX - REMOVAL)(3) Remove the trailer hitch. (Refer to 13 - FRAME
& BUMPERS/FRAME/TRAILER HITCH -
REMOVAL)
(4) Raise and support the frame so the tires are off
floor.
(5) Remove the shock absorbers. (Refer to 2 - SUS-
PENSION/REAR/SHOCK - REMOVAL)
(6) Remove the rear leaf spring shackle bolts and
let the axle rest on the ground. (Fig. 21)
(7) Remove the spare wheel.
(8) Remove the clip and remove the spare tire
winch tube. (Fig. 22)
Fig. 21 REAR SPRING
1 - SPRING SHACKLE
2 - LEAF SPRING EYE BOLT/NUT
3 - REAR LEAF SPRING
Fig. 22 SPARE TIRE WINCH TUBE
1 - SPARE TIRE WINCH ASSEMBLY
2 - HAIR PIN CLIP
3 - WINCH TUBE
4 - H-SECTION/SPARE WHEEL SUPPORT
DRFRAMES & BUMPERS 13 - 15
FRAME (Continued)

FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY - GAS....................1
FUEL INJECTION - GAS...................24FUEL DELIVERY - DIESEL.................56
FUEL INJECTION - DIESEL................79
FUEL DELIVERY - GAS
TABLE OF CONTENTS
page page
FUEL DELIVERY - GAS
DESCRIPTION..........................1
OPERATION............................2
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE...................2
SPECIFICATIONS
FUEL SYSTEM PRESSURE..............3
TORQUE - FUEL SYSTEM...............3
SPECIAL TOOLS
FUEL SYSTEM........................5
FUEL FILTER/PRESSURE REGULATOR
DESCRIPTION..........................6
OPERATION............................6
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION..........................7
OPERATION............................7
REMOVAL.............................7
INSTALLATION..........................8
FUEL LINES
DESCRIPTION..........................8
QUICK CONNECT FITTING
DESCRIPTION..........................8
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS............................8FUEL PUMP
DESCRIPTION.........................12
OPERATION...........................12
FUEL PUMP MODULE
DESCRIPTION.........................12
OPERATION...........................12
REMOVAL.............................12
INSTALLATION.........................13
FUEL RAIL
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL.............................13
INSTALLATION.........................18
FUEL TANK
DESCRIPTION.........................20
OPERATION...........................20
REMOVAL- EXCEPT DIESEL..............20
INSTALLATION - EXCEPT DIESEL..........22
INLET FILTER
REMOVAL.............................23
INSTALLATION.........................23
FUEL DELIVERY - GAS
DESCRIPTION
The fuel delivery system consists of:
²a 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
²fuel tubes/lines/hoses
²a combination fuel filter/fuel pressure regulator²quick-connect fittings
²fuel injector rail
²fuel tank
²fuel tank filler/vent tube assembly
²fuel tank filler tube cap
²accelerator pedal
²throttle cable
Certain fuel delivery components can be found in
(Fig. 1).
DRFUEL SYSTEM 14 - 1