Dodge ram truck 3500 1996 Service Manual page 1342

14 -108 FUEL SYSTEM
BR
REMOVAL AND INSTALLATION (Continued)
J9414-96
Fig. 114 Pump Removal/installation
REMOVAL
(1) Disconnect both negative battery cables at both
batteries.
(2) Remove starter motor. Refer to Group 8B for
procedures.
(3) Place a drain pan below the pump.
(4) Remove the fuel line fittings at the top of both
the fuel pump and fuel heater housing (Fig. 114).
(5) - Remove the fuel hose clamps and rubber fuel
hose (fuel heater housing-to-fuel pump)'(Fig. 114).
(6) Remove the two mounting bolts (Fig. 114).
(7) Remove the fuel pump and fuel heater assem­
bly from the engine as one unit.
CAUTION; Do not allow pump plunger to catch on
edge of hole in cylinder block during removal.
Plunger may slide out and drop into engine.
INSTALLATION
(1) Clean the mating surfaces of the fuel heater
mounting bracket, the fuel pump and the engine
block of any gasket material.
(2) Position the new gaskets, the fuel heater hous­
ing mounting bracket and the fuel pump to the
engine.
(3) Install the two mounting bolts into the engine.
Tighten to 24 N-m (18 ft. lbs.) torque. As these bolts
are tightened, the plunger w i t h i n the fuel pump
is being compressed. Tighten these two bolts
alternately to prevent damage to the fuel pump
housing.
(4) Install fuel line fittings to pump and fuel
heater. Tighten to 24 N-m (18 ft. lbs.) torque.
(5) Install starter motor. Refer to Group 8B for
procedures.
(6) Connect battery cables at both batteries.
(7) Bleed air from fuel system. Refer to the Air
Bleed Procedure.
FUEL
TANK
PiESSUFtE FtELlEF/ROLLOWER W A L W E
Refer to Fuel Tank Module for procedures.
HIGH-PRESSURE FUEL LINES
All high-pressure fuel lines are of the same length
and inside diameter. Correct high-pressure fuel line
usage and installation is critical to smooth engine
operation.
CAUTION: The high-pressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld high-pressure fuel lines or to
repair lines that are damaged. Only use the recom­
mended lines when replacement of high-pressure
fuel line is necessary.
REMOVAL
(1) Disconnect both negative battery cables from
both batteries.
(2) Remove the nameplate/cover from the top of
the six engine valve covers (two nuts) (Fig. 115).
NAMEPLATE/COVER
NUTS (2)
NAMEPLATE/COVER
#6 CYLINDER
VALVE COVER
CLAMPS (2)
METAL
INTAKE
TUBE
RUBBER
ADAPTER
J9414-73
Fig. 115 Nameplate/Cover—Diesei
(3) Remove the necessary clamps holding the lines
to the engine.
(4) Clean the area around each line. Disconnect
each line at the top of each fuel injector (Fig. 116).
(5) Disconnect each high-pressure line fitting at
each fuel injection pump delivery valve holder (Fig.
117).
(6) Very carefully remove each line from the
engine. Do not bend the line while removing.