Dodge RAM TRUCK 1500 1995 Service Manual page 1182

14-100 GENERAL DIAGNOSIS—DIESEL ENGINE ~ , _ _ BR
VISUAL INSPECTION
A visual inspection for loose, disconnected, or incor­
rectly routed wires and hoses should be made before
attempting to diagnose or service the diesel fuel in­
jection system. A visual check will help find these
conditions. It also saves unnecessary test and diag­
nostic time. A thorough visual inspection of the fuel
injection system includes the following checks:
(1) Be sure that the battery connections (on both
batteries) are tight and not corroded.
(2) Be sure that the 60-way connector is fully en­
gaged with the powertrain control module (PCM).
Verify that the connector mounting screw is tight
(Fig. 2).
DATA LINK
CONNECTOR
POWERTRAIN CONTROL
MODULE (PCM)
Fig. 2 PCM Location—Typical
J9414-11
(3) Be sure that the electrical connections at the
intake manifold air heater relays (Fig. 3) are tight
and not corroded.
(4) Inspect the starter motor and starter solenoid
connections for tightness and corrosion.
(5) Verify that the electrical connector is firmly
connected to the intake manifold air temperature
sensor. Inspect the connector for corrosion or dam­
aged wires. The sensor is located on the top of the in­
take manifold (Fig. 4).
(6) Verify that the water-in-fuel (WIF) sensor elec­
trical connector is firmly attached to the sensor (Fig.
5). Inspect the connector for corrosion or damaged
wires.
(7) Check for water in the fuel filter/water separa­
tor. A water drain is supplied on the filter/separator.
Refer to Fuel Filter/Water Separator in the Diesel
Engine—Component Removal/Installation section of
this group for draining water.
(8) Verify that the electrical connector is firmly
connected to the fuel shutdown solenoid on the injec­
tion pump (Fig. 4). Inspect the connector for corro­
sion or damage.
CABLES TO
BATTERY (+)
BATTERY
(LEFT SIDE)
INTAKE AIR
HEATER RELAYS (2)
RELAY
TRIGGER
WIRES (4)
RELAY MOUNTING ^
BOLTS (3)
J9414-85
Fig. 3 Intake Manifold Air Heater Relays
FRONT OF ENGINE
AIR TEMPERATURE
SENSOR
SENSOR
ELECTRICAL
CONNECTOR
INTAKE
MANIFOLD
(UPPER HALF)
FUEL
SHUTDOWN
SOLENOID
SOLENOID
ELECTRICAL
CONNECTOR
J9414-93
Fig. 4 Air Temperature Sensor and Fuel Shutdown
Solenoid
(9) Be sure that the intake manifold air heater
electrical cable connections at the intake manifold
are tight and free of corrosion (Fig. 6).
(10) Inspect the throttle linkage and accelerator
linkage for binding.
(11) Be sure that the throttle return spring is con­
nected.
(12) Inspect all fuel supply and return lines for
signs of leakage.
(13) Be sure that the ground connections are tight