Dodge ram truck 3500 1996 Service Manual page 1250

14 - 16 FUEL SYSTEM B R
R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d )
INSTALLATION
CAUTION; Whenever the fuel pump module is ser­
viced, the locknut and gasket must be replaced.
(1) Using a new gasket, position fuel pump module
into opening in fuel tank.
( 2 ) Position new locknut over top of fuel pump
module.
(3) Install Special Tool 6856 to locknut.
(4) Tighten locknut to 54 N-m (40 ft. lbs.) torque.
(5) Install fuel tank. Refer to Fuel Tank Installa­
tion in this section.
FUEL PUMP INLET STRAINER
The fuel pump inlet strainer (in-tank fuel filter) is
not serviced separately. I f i t needs service, the fuel
pump module assembly must be replaced. Refer to
Fuel Pump Module Removal/Installation.
FUEL LEVEL SENSOR
The fuel level sensor (fuel gauge sending unit) is
not serviced separately. I f i t needs service, the fuel
pump module assembly must be replaced. Refer to
Fuel Pump Module Removal/Installation.
FUEL INJECTOR RAIL—3.9L/5.2L/5.9L ENGINES
WARNING: THE F U E L SYSTEM IS UNDER A CON­
STANT P R E S S U R E (EVEN WITH THE ENGINE
TURNED OFF). B E F O R E SERVICING THE F U E L
RAIL ASSEMBLY, THE F U E L SYSTEM P R E S S U R E
MUST B E R E L E A S E D .
To release fuel pressure, refer to the Fuel System
Pressure Release Procedure found in this group.
CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate the rail
halves at the connecting hose (Fig. 25). Due to the
design of this connecting hose, it does use any
clamps. Never attempt to install a clamping device
of any kind to the hose. When removing the fuel rail
assembly for any reason, be careful not to bend or
kink the connecting hose.
REMOVAL
(1) Remove negative battery cable at battery.
(2) Remove air cleaner.
(3) Perform the fuel pressure release procedure.
(4) Remove throttle body from intake manifold.
Refer to Throttle Body removal in this group.
(5) I f equipped with air conditioning, remove the
A-shaped A/C compressor-to-intake manifold support
bracket (three bolts) (Fig. 26).
(6) Disconnect electrical connectors at all fuel
injectors (Fig. 27). The factory fuel injection wiring
Fig. 25 Fuel Rail Assembly—Typical
AIR CONDITIONING
/COMPRESSOR SUPPORT BRACKET
MOUNTING BOLTS
J9214-49
Fig. 26 A/C Compressor Support Bracket—Typical
harness is numerically tagged (INJ 1, I N J 2, etc.) for
injector position identification.
(7) 3.9L (V-6) engine only: Disconnect electrical
connector at intake manifold air temperature sensor.
Do not remove sensor.
(8) Remove duty cycle EVAP canister purge sole­
noid/bracket assembly (Fig. 28) from intake manifold.
(9) Disconnect fuel tube (line) at side of fuel rail.
Refer to Quick-Connect Fittings for procedures,
(10) Remove the remaining fuel rail mounting
bolts.
(11) Gently rock and pull the left fuel rail until
the fuel injectors just start to clear the intake mani­
fold. Gently rock and pull the r i g h t fuel rail until
the fuel injectors just start to clear the intake mani-