Dodge ram truck 3500 1996 Service Manual page 1253

FUEL SYSTEM 14 - 1 9
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 )
NOTE: The fuel injector electrical connectors on
all 10 injectors should be facing to the right (pas­
senger) side of the vehicle (Fig. 32).
(3) Position the fuel rail/fuel Injector assembly to
the injector openings on the intake manifold.
(4) Guide each injector into the intake manifold.
Be careful not to tear the injector o-ring.
(5) Push the r i g h t fuel rail down until fuel injec­
tors have bottomed on injector shoulder. Push the
left fuel rail down until fuel injectors have bottomed
on injector shoulder.
(6) Install the six fuel rail mounting bolts into the
lower half of intake manifold. Tighten bolts to 15
N-m (136 in. lbs.) torque.
(7) Connect wiring to all fuel injectors. The injec­
tor wiring harness is numerically tagged.
(8) Install upper half of intake manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedures.
(9) Connect main fuel line at fuel rail. Refer to
Quick-Connect Fittings for procedures.
(10) Install ignition coil pack and bracket assem­
bly at intake manifold and right engine valve cover
(four bolts).
(11) Install throttle body to intake manifold. Refer
to Throttle Body removal in this group.
(12) Install throttle body linkage to throttle body.
(13) Install air cleaner tube and housing.
(14) Install negative battery cable at battery.
(15) Start engine and check for leaks.
FUEL INJECTOR(S)—ALL GAS 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
INJECTOR(S), 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.
To remove one or more fuel injectors, the fuel rail
assembly must be removed from engine.
REMOVAL
(1) Remove air cleaner assembly.
(2) Remove fuel injector rail assembly. Refer to
Fuel Injector Rail removal in this section.
(3) Remove the clip(s) retaining the injector(s) to
fuel rail (Fig. 29) or (Fig. 30).
(4) Remove injector(s) from fuel rail.
INSTALLATION
(1) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(2) Install injector(s) and injector clip(s) to fuel
rail.
(3) Install fuel rail assembly. Refer to Fuel Injector
Rail installation.
(4) Install air cleaner.
(5) Start engine and check for leaks.
FUEL TANK—ALL ENGINES
DRAINING FUEL TANK
(1) Remove fuel tank filler tube cap to release fuel
tank pressure.
(2) Perform Fuel System Pressure Release proce­
dure as described in this group.
(3) Raise vehicle on hoist.
(4) While working over the left rear tire/wheel, dis­
connect the rubber fuel fill hose and clamp at fuel
tank (Fig. 33). Position fuel siphoning/drain hose into
this opening at tank.
F U E L
P U M P
M O D U L E ,
VENT TUBE
AND H O S E
F U E L
TANK
F U E L T A N K
FILLER T U B E
CAP
F U E L FILL
T U B E AND H O S E
DRIVER'S mm
OF VEHICLE
C L A M P S ( 4 )
J 9 4 1 4 - 3 6
Fig. 33 Fuel Tank Fill and Vent Hoses
(5) Drain fuel into an approved portable holding
tank or a properly labeled gasoline safety container.
TANK REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Remove fuel tank filler tube cap.
WARNING: THE F U E L SYSTEM IS UNDER A CON­
STANT P R E S S U R E EVEN WITH THE ENGINE OFF.
B E F O R E SERVICING THE F U E L TANK, F U E L S Y S ­
TEM P R E S S U R E MUST B E R E L E A S E D . R E F E R TO
THE F U E L SYSTEM P R E S S U R E R E L E A S E PROCE­
DURE B E F O R E SERVICING THE FUEL TANK.