Dodge ram truck 3500 1996 Service Manual page 1244

14 - 11
FUEL
SYSTEM
mm
SERWiCE P R O C E D U R E S (Continued)
FUEL
SYSTEM
PRESSURE
RELEASE
PROCEDURE—WITHOUT
PRESSURE
TEST PORT
Use the following procedure i f the fuel r a i l is
not equipped w i t h a fuel pressure test port.
(1) Remove the Fuel Pump relay from the Power
Distribution Center (PDC). For location of the relay,
refer to the label on the underside of the PDC cover.
(2) Start and run engine i t stalls.
(3) Attempt restarting engine until it will no
longer run.
(4) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel f r o m within the fuel rail.
Do not attempt to use the following steps t o relieve
this pressure as excessive fuel will be forced into a
cylinder chamber.
(5) Unplug connector from any injector.
(6) Attach one end of a jumper' wire with alligator
clips (18 gauge or smaller) to either injector terminal.
(7) Connect the other end of the jumper wire to
the positive side of the battery.
(8) Connect one end of a second jumper wire to the
remaining injector terminal.
CAUTION: Supplying power to an injector for more
than 4 seconds will permanently damage the injec­
tor. Do not leave the injector connected to power
for more than 4 seconds.
(9) Momentarily touch the other end of this
jumper wire to the negative terminal of the battery
for no more than 4 seconds.
(10) Place a rag or towel below the fuel line at the
quick connect to the rail..
(11) Disconnect the quick connect fitting to the
rail. Refer to Quick-Connect Fittings in this section.
(12) Return the fuel pump relay to the PDC.
(13) One or more Diagnostic Trouble Codes (DTCs)
may have been stored in the PCM memory due to
fuel pump relay removal. The DRB scan tool must be
used to erase a DTC. Refer to Group 25, Emission
Control System. See On-Board Diagnostics.
FUEL TUBES/LINES/HOSES AND CLAMPS
Also refer to the section on Quick-Connect Fittings.
WARNING: THE FUEL SYSTEM IS UNDER A CON­
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES, FIT­
TINGS OR LINES, THE FUEL SYSTEM PRESSURE
MUST BE RELEASED. REFER TO THE FUEL SYSTEM
PRESSURE R E L E A S E PROCEDURE IN THIS GROUP.
leaks are not present. The component should be
replaced immediately i f there is any evidence of deg­
radation that could result in failure.
Never attempt to repair a plastic fuel line/tube.
Replace as necessary.
Avoid contact of any fuel tubes/hoses with other vehi­
cle components that could cause abrasions or scuffing.
Be sure that' the plastic fuel lines/tubes are properly
routed to prevent pinching and to avoid heat sources.
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 contaminated fuel
in this system. I f it is necessary to replace these lines/
tubes/hoses, only those marked EFM/EFI may be used.
The hose clamps used to secure rubber hoses on
fuel injected vehicles are of a special rolled edge con­
struction. 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. A l l other types of clamps may cut into the
hoses and cause high-pressure fuel leaks.
Use new original equipment type hose clamps.
Tighten hose clamps to 1 N-m (15 in. lbs.) torque.
QUICK-CONNECT FITTINGS
Also refer to the Fuel Tubes/Lines/Hoses and
Clamps section.
Different types of quick-connect fittings are used to
attach various fuel system components. These are: a
single-tab type, a two-tab type, a plastic retainer ring
type or a latch clip type. Certain fittings may require
the use of a special tool for disconnection.
SINGLE-TAB TYPE
This type of fitting is equipped with a single pull
tab (Fig. 11). The tab is removable. After the tab is
removed, the quick-connect fitting can be separated
from the fuel system component.
/ PRESS HERE
INSERTED TO REMOVE
TUBE END PULL TAB J9414-24
Inspect all hose connections such as clamps, cou­
plings and fittings to make sure they are secure and
Fig. 11 Single-Tab Type Fitting