Dodge ram truck 3500 1996 Service Manual page 1237

B R
FUEL SYSTEM 14 - 3
FUEL DELIVERY SYSTEM-6ASOLINE ENGINE
page
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM 3
FUEL FILTER/FUEL P R E S S U R E REGULATOR . . . 4
FUEL GAUGE SENDING UNIT 4
FUEL INJECTORS—3.9L/5.2L/5.9L ENGINES 5
FUEL INJECTORS—8.0L ENGINE 5
FUEL PUMP MODULE 3
FUEL PUMP 3
FUEL RAIL—3.9L/5.2L/5.9L ENGINES 5
FUEL RAIL—8.0L ENGINE 6
FUEL TANK FILLER TUBE CAP 6
FUEL TANK 5
QUICK-CONNECT FITTINGS 6
DIAGNOSIS AND TESTING
FUEL GAUGE SENDING UNIT 8
FUEL INJECTORS 8
FUEL PUMP P R E S S U R E TEST-ALL ENGINES
WITHOUT P R E S S U R E T E S T PORT 7
FUEL PUMP P R E S S U R E TEST—ALL ENGINES
WITH P R E S S U R E T E S T PORT 6
SERVICE PROCEDURES
FUEL SYSTEM P R E S S U R E R E L E A S E
PROCEDURE—WITHOUT P R E S S U R E T E S T
PORT 10
D E S C R I P T I O N A N D O P E R A T I O N
FUEL DELIVERY SYSTEM
The fuel delivery system consists of: the electric
fuel pump, fuel filter/fuel pressure regulator, fuel
tubes/lines/hoses, fuel rail, fuel injectors, fuel tank,
accelerator pedal and throttle cable.
A fuel return system is used on all models (all gas
powered engines). 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 no longer
used with any gas powered engine.
The fuel tank assembly consists of: the fuel tank,
filler tube, fuel gauge sending unit/electric fuel pump
module, a pressure relief/rollover valve and a pres­
sure-vacuum filler 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 atmo­
sphere. The description and function of the Evapora­
tive Control System is found in Group 25, Emission
Control Systems.
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FUEL SYSTEM PRESSURE RELEASE
PROCEDURE-WITH PRESSURE TEST
PORT . 8
FUEL TUBES/LINES/HOSES AND CLAMPS . . . . 10
QUICK-CONNECT FITTINGS . . . . . . . 10
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL 21
FUEL FILTER/FUEL PRESSURE REGULATOR . . 15
FUEL INJECTOR RAIL—3.9L/5.2L/5.9L
ENGINES 16
FUEL INJECTOR RAIL—8.0L V-10 ENGINE . . . . 18
FUEL INJECTOR(S)—ALL GAS ENGINES . . . . . 19
FUEL LEVEL SENSOR 16
FUEL PUMP INLET STRAINER 16
FUEL PUMP MODULE 15
FUEL PUMP RELAY . 15
FUEL TANK—ALL ENGINES 19
THROTTLE CABLE . 22
SPECIFICATIONS
FUEL SYSTEM PRESSURE 23
FUEL TANK CAPACITY
23
TORQUE SPECIFICATIONS 23
VECI LABEL SPECIFICATIONS . . . . . . . . . . . . . 23
FUEL P U i P MODULE
The fuel pump module on all gas powered engines
is installed in the top of the fuel tank (Fig. 1). The
fuel pump module (Fig. 1) or (Fig. 2) contains the fol­
lowing:
• A combination fuel filter/fuel pressure regulator
• Electric fuel pump
• Fuel pump reservoir
© A separate in-tank fuel filter
© Pressure relief/rollover valve
• Fuel gauge sending unit
• Fuel supply line connection
• Auxiliary fuel supply fitting (not all engines)
FUEL P U i P
The fuel pump used in this system has a perma­
nent magnet electric motor. The pump is part of the
fuel pump module (Fig. 1). The fuel pump module is
suspended in fuel in the fuel tank. Fuel is drawn in
through a filter and pushed through the electric
motor to the outlet. The pump contains a check
valve. This valve is located near the pump outlet. It
restricts fuel movement in either direction to main­
tain fuel supply line pressure when the pump is not