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FRAMES & BUMPERS
13 - 22
FRAME (Continued)DR
DR FRAME (Continued) SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION Cab mount bolts Cargo box bolts
Front crossmember bolts - 2WD Front crossmember bolts - 4WD
Front skid plate bolts
Lower bumper support bracket bolt Radiator crossmember bolts - lower Radiator crossmember bolts - upper
Rear crossmember - 2WD Rear crossmember - 4WD Rear spring shackle bolts
Spare tire winch bolts
Trailer hitch reinforcement bracket bolt
Transfercase skid plate bolts
Transercase skid plate crossmember bolts Transmission mount to crossmember nuts
FRONT CROSSMEMBER REMOVAL
N·m 81
108
61
102
34
54
28
28
102
102
163
41
170
34
34
61FRAMES & BUMPERS
13 - 23
Ft. Lbs.
In. Lbs.
60
80
45
75
25
40
21
21
75
75
120
30
125
25
25
45— — — — — — — — — — — — — — — —
(1) Raise and support
to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)
the vehicle.
(Refer
(2) Remove the front skid plate, if equipped. (Refer to 13 - FRAME & BUMPERS/FRAME/FRONT SKID PLATE - REMOVAL)
(3) Remove the bolts and remove the crossmember.
(Fig. 29) or (Fig. 30)
INSTALLATION
(1) Install the crossmember. (2) Install the bolts; † On 2WD vehicles, tighten the bolts to 61 N·m † On 4WD vehicles, tighten the bolts to 102 N·m
(45 ft. lbs.).
(75 ft. lbs.).
Fig.29FRONTCROSSMEMBER-2WD
1 - CROSSMEMBER 2 - BOLTS (2 PER SIDE)
FRAMES & BUMPERS
13 - 24
FRONT CROSSMEMBER (Continued)DR
INSTALLATION
(1) Snap the rear tabs over the front crossmember
and install the skid plate.
(2) Install the bolts and tighten to 34 N·m (25 ft.
lbs.).
TRANSMISSION CROSSMEMBER REMOVAL
(1) Raise and support
to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)
the vehicle.
(Refer
(2) Remove
equipped. FRAME/TRANSFER REMOVAL)
the
transfercase
if (Refer to 13 - FRAME & BUMPERS/
PLATE
CASE
plate,
SKID
skid
(3) Support the transmission with a suitable lifting
device.
or (Fig. 33)
(4) Remove the transmission mount nuts. (Fig. 32)
(5) Remove the bolts and remove the crossmember.
Fig.30FRONTCROSSMEMBER-4WD
1 - BOLTS (2 PER SIDE) 2 - CROSSMEMBER
(3) Install the front skid plate, if equipped. (Refer to 13 - FRAME & BUMPERS/FRAME/FRONT SKID PLATE - INSTALLATION)
FRONT SKID PLATE REMOVAL
(1) Raise and support
to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)
the vehicle.
(Refer
(2) Remove the bolts. (Fig. 31) (3) Slide skid plate back off of the crossmember
and remove.
Fig.32REARCROSSMEMBER-2WD
1 - TRANSMISSION MOUNT 2 - REAR CROSSMEMBER 3 - TRANSMISSION MOUNT NUTS (2) 4 - CROSSMEMBER BOLTS (2 PER SIDE)
Fig.31FRONTSKIDPLATE
1 - FRONT CROSSMEMBER 2 - FRONT SKID PLATE 3 - BOLTS (2)
DR TRANSMISSION CROSSMEMBER (Continued)
FRAMES & BUMPERS
13 - 25
(4) Remove the rear two cargo box bolts and loosen the remaining bolts. (Refer to 23 - BODY/EXTERI- OR/CARGO BOX - REMOVAL)
(5) Using a suitable lifting device, lift and support
the rear of the cargo box and remove the hitch.
Fig.33REARCROSSMEMBER-4WD
1 - TRANSMISSION MOUNT 2 - TORSION BAR 3 - CROSSMEMBER BOLTS (3 PER SIDE) 4 - REAR CROSSMEMBER 5 - TRANSMISSION MOUNT NUTS (2)
INSTALLATION
(1) Install the crossmember and install the bolts. (2) Tighten the bolts to 102 N·m (75 ft. lbs.). (3) Install
transmission mount nuts and
the
tighten to 61 N·m (45 ft. lbs.).
(4) Remove the transmission support. (5) Install the transfercase skid plate. (Refer to 13
- FRAME & BUMPERS/FRAME/TRANSFER CASE SKID PLATE - INSTALLATION)TRAILER HITCH REMOVAL
(1) Remove the rear bumper.
to 13 - FRAME & BUMPERS/BUMPERS/REAR BUMPER - REMOVAL)
(Refer
(2) Remove the hitch bolts. (Fig. 34) (3) Disconnect all wire harness support push pins.
Fig.34TRAILERHITCH
1 - HITCH 2 - HITCH BOLTS (4) 3 - BUMPER BRACKET BOLTS (4) 4 - BUMPER SUPPORT BRACKETS
INSTALLATION
(1) Install the hitch onto the frame rails and make sure the locators on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly.
(2) Lower the cargo box and install the rear bolts. (Refer to 23 - BODY/EXTERIOR/CARGO BOX - INSTALLATION)
(3) Install the hitch bolts and tighten to 170 N·m
(125 ft. lbs.).
(4) Connect all wire harness support push pins. (5) Install the rear bumper. (Refer to 13 - FRAME & BUMPERS/BUMPERS/REAR BUMPER - INSTAL- LATION)
13 - 26
FRAMES & BUMPERS
DR
TRANSFER CASE SKID PLATE REMOVAL
FRONT TOW HOOK ASSEMBLY REMOVAL
(1) Raise and support
to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)
the vehicle.
(Refer
(2) Support the skid plate and remove the bolts.
(Fig. 35)
(3) Remove the skid plate. (4) Support
skid plate
the
remove the bolts.
(5) Remove the skid plate crossmember.
crossmember and
Fig.35TRANSFERCASESKIDPLATE
1 - CROSSMEMBER BOLTS (4) 2 - SKID PLATE CROSSMEMBER 3 - SKID PLATE 4 - SKID PLATE BOLTS (4)
INSTALLATION
(1) Install the skid plate crossmember and install
the bolts.
(2) Tighten the bolts to 34 N·m (25 ft. lbs.). (3) Install the skid plate and install the bolts. (4) Tighten the bolts to 34 N·m (25 ft. lbs.).
(1) Remove front bumper. (Refer to 13 - FRAME &
BUMPER
BUMPERS/BUMPERS/FRONT REMOVAL)
(2) Remove the bolts and remove the tow hook
assembly. (Fig. 36)
Fig.36FRONTTOWHOOKASSEMBLY
1 - BUMPER CENTER SUPPORT BRACKET 2 - BOLTS (6) 3 - TOW HOOK ASSEMBLY
INSTALLATION
(1) Install the tow hook assembly and bolts hand
(2) Install the front bumper. (Refer to 13 - FRAME
& BUMPERS/BUMPERS/FRONT INSTALLATION)
BUMPER
(3) Tighten the tow hook bolts to 68 N·m (50 ft.
tight.
lbs.).
DR
FUEL SYSTEM 14 - 1
FUEL SYSTEM
TABLE OF CONTENTS
FUEL DELIVERY - GAS . . . . . . . . . . . . . . . . . . . . 1
FUEL INJECTION - GAS . . . . . . . . . . . . . . . . . . . 24FUEL DELIVERY - DIESEL FUEL INJECTION - DIESEL
. . . . . . . . . . . . . . . . . 56
. . . . . . . . . . . . . . . . 79page
page
FUEL DELIVERY - GAS
TABLE OF CONTENTS
page
page
FUEL DELIVERY - GAS
FUEL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE - FUEL SYSTEMPRESSURE RELEASE . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . 3
TORQUE - FUEL SYSTEM . . . . . . . . . . . . . . . 3DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12FUEL PUMP MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13SPECIAL TOOLS
FUEL RAIL
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL FILTER/PRESSURE REGULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18FUEL LEVEL SENDING UNIT / SENSOR
FUEL TANK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . 20
REMOVAL- EXCEPT DIESEL INSTALLATION - EXCEPT DIESEL . . . . . . . . . . 22FUEL LINES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
QUICK CONNECT FITTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - QUICK-CONNECTFITTINGS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL DELIVERY - GAS DESCRIPTION
The fuel delivery system consists of: † a fuel pump module containing the electric fuel pump, fuel filter/fuel pressure regulator, fuel gauge sending unit (fuel level sensor) and a secondary fuel filter located at the bottom of the pump module † fuel tubes/lines/hoses † a combination fuel filter/fuel pressure regulator
INLET FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23† quick-connect fittings † fuel injector rail † fuel tank † fuel tank filler/vent tube assembly † fuel tank filler tube cap † accelerator pedal † throttle cable Certain fuel delivery components can be found in
(Fig. 1).
FUEL DELIVERY - GAS
14 - 2
FUEL DELIVERY - GAS (Continued)DR
Fig.1FUELDELIVERYCOMPONENTS
1 - FUEL TANK 2 - CHECK VALVE 3 - LIQUID EXPANSION CHAMBER 4 - FUEL FILTER / FUEL PRESSURE REGULATOR 5 - QUICK-CONNECT FITTING AND FUEL LINE (TO ENGINE) 6 - EVAP LINE CONNECTION 7 - LEAK DETECTION PUMP FRESH AIR LINE
8 - LDP FRESH AIR FILTER 9 - LEAK DETECTION PUMP 10 - EVAP CANISTERS (2) 11 - FUEL TANK STRAPS (2) 12 - CHECK VALVE 13 - FUEL PUMP MODULE LOCK RING 14 - FUEL PUMP MODULE
OPERATION
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 not used.
The fuel tank assembly consists of: the fuel tank, fuel pump module assembly, fuel pump module lock- nut/gasket, and fuel tank check valve (refer to Fuel Tank Check Valve for information).
A fuel filler/vent tube assembly using a pressure/ vacuum, 1/4 turn fuel filler cap is used. The fuel filler tube contains a flap door located below the fuel fill 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 Emission Control Systems.
Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service. They do not require normal sched- uled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so.
STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE
Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port.
(1) Remove fuel fill cap.
DR FUEL DELIVERY - GAS (Continued)
(2) Remove fuel pump relay from Power Distribu- tion Center (PDC). For location of relay, refer to label on underside of PDC cover.
(3) Start and run engine until it stalls. (4) Attempt restarting engine until
it will no
longer run.
(5) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cyl- inder chamber.
(6) Unplug connector from any fuel injector. (7) Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. (8) Connect other end of jumper wire to positive
side of battery.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
339 kPa +/- 34 kPa (49.2 psi +/- 2 psi).
TORQUE - FUEL SYSTEM
DESCRIPTION
Accelerator Pedal Bracket
Mounting
Accelerator Pedal Position Sensor Bracket-to-Battery
Tray Bolts
Crankshaft Position
Sensor - 3.7L
Crankshaft Position
Sensor - 4.7L
Crankshaft Position
Sensor - 5.7L
Crankshaft Position
Sensor - 5.9L
Crankshaft Position
Sensor - 8.0L
Camshaft Position Sensor
- 3.7L
Camshaft Position Sensor
- 4.7L
Camshaft Position Sensor
- 5.7L
Camshaft Position Sensor
- 8.0L
N-m 12
28
28
12
12
12
12
FUEL DELIVERY - GAS
14 - 3
(9) Connect one end of a second jumper wire to
remaining injector terminal.
CAUTION: Powering an injector for more than a few seconds will permanently damage the injector.
(10) Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds.
(11) Place a rag or towel below fuel line quick-con-
nect fitting at fuel rail.
(12) Disconnect quick-connect fitting at fuel rail.
Refer to Quick-Connect Fittings.
(13) Return fuel pump relay to PDC. (14) One or more Diagnostic Trouble Codes (DTC’s) may have been stored in PCM memory due to fuel pump relay removal. The DRBt scan tool must be used to erase a DTC.
Ft. Lbs.
21
21
In. Lbs.
105
30
105 (+/-20)
70
70
106
106
105 (+/-) 20
50
FUEL DELIVERY - GAS
14 - 4
FUEL DELIVERY - GAS (Continued)DR
DESCRIPTION Engine Coolant
Temperature Sensor -
3.7L
Engine Coolant
Temperature Sensor -
4.7L
Engine Coolant
Temperature Sensor -
5.7L
Engine Coolant
Temperature Sensor -
5.9L
Engine Coolant
Temperature Sensor -
8.0L
EVAP Canister- to-Bracket
Nuts
EVAP Canister-to-frame
bolts
Fuel Filler Hose Clamp at
Tank
Fuel Filler Housing-to-
Body Screws
Fuel Pump Module Lock
Ring
Fuel Rail Mounting Bolts -
3.7L
Fuel Rail Mounting Bolts -
4.7L
Fuel Rail Mounting Bolts -
5.7L
Fuel Rail Mounting Bolts -
5.9L
Fuel Rail Mounting Bolts -
8.0L
Fuel Tank Mounting Straps
IAC Motor Mounting
Screws - 3.7L
IAC Motor Mounting
Screws - 4.7L
IAC Motor Mounting
Screws - 5.9L
IAC Motor Mounting
Screws - 8.0L
Leak Detection Pump
Mounting Bolt
Map Sensor Mounting
Screws - 3.7L
N-m 11
11
11
11
11
8.5
34
54
11
11
11
23
15
41
8.5
Ft. Lbs.
In. Lbs.
25
40
30
96
96
96
96
96
75
30
17
100
100
100
200
136
60
60
60
60
75
25
DR FUEL DELIVERY - GAS (Continued)
FUEL DELIVERY - GAS
14 - 5
DESCRIPTION
Map Sensor Mounting
Screws - 4.7L
Map Sensor Mounting
Screws - 5.9L
Map Sensor Mounting
Screws - 8.0L
PCM-to-Mounting Bracket
Mounting Screws
Power Steering Pressure
Switch - 3.7L
Power Steering Pressure
Switch - 4.7L
TPS Mounting Screws -
3.7L
TPS Mounting Screws -
4.7L
TPS Mounting Screws -
5.9L
TPS Mounting Screws -
8.0L
Throttle Body Mounting
Bolts - 3.7L
Throttle Body Mounting
Bolts - 4.7L
Throttle Body Mounting
Bolts - 5.7L
Throttle Body Mounting
Bolts - 5.9L
Throttle Body Mounting
Bolts - 8.0L
Oxygen Sensors
SPECIAL TOOLS
FUEL SYSTEM
N-m
Ft. Lbs.
In. Lbs.
14-22
14-22
11
12
12
23
22
30
22
25
25
20
35
124-195
124-195
60
60
60
60
100
105
105
200
192
FUELPRESSURETESTER-#8978
TESTKIT,FUELPRESSURE,8.0LENGINE-#5069
FUEL DELIVERY - GAS
14 - 6
FUEL DELIVERY - GAS (Continued)ADAPTERS,FUELPRESSURETEST,8.0L-#6539
AND/OR#6631
DR
FUEL FILTER/PRESSURE REGULATOR DESCRIPTION
A combination fuel filter and fuel pressure regula- tor (Fig. 2) is used on all engines. It is located on the top of the fuel pump module. A separate frame mounted fuel filter is not used with any engine.
Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service. They do not require normal sched- uled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so.
SPANNERWRENCH-#6856
FITTING,AIRMETERING-#6714
Fig.2SIDEVIEW-FILTER/REGULATOR
1 - INTERNAL FUEL FILTER 2 - FUEL FLOW TO FUEL INJECTORS 3 - FUEL FILTER/FUEL PRESSURE REGULATOR 4 - EXCESS FUEL BACK TO TANK 5 - FUEL INLET 6 - RUBBER GROMMET 7 - TOP OF PUMP MODULE
O2S(OXYGENSENSOR)REMOVER/INSTALLER-
#C-4907
OPERATION
Fuel Pressure Regulator Operation: The pres- sure regulator is a mechanical device that is not con- trolled by engine vacuum or the Powertrain Control Module (PCM).
The regulator is calibrated to maintain fuel system operating pressure of approximately 339 kPa ± 34
kPa (49.2 psi ± 5 psi) at the fuel injectors. It contains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter (Fig. 2) is also part of the assembly.Fuel is supplied to the filter/regulator by the elec- tric fuel pump through an opening tube at the bot- tom of filter/regulator (Fig. 2).
The regulator acts as a check valve to maintain some fuel pressure when the engine is not operating. This will help to start the engine. A second check valve is located at the outlet end of the electric fuel
DR FUEL FILTER/PRESSURE REGULATOR (Continued)
FUEL DELIVERY - GAS
14 - 7
pump. Refer to Fuel Pump - Description and Operation for more information.
If fuel pressure at the pressure regulator exceeds approximately 49.2 psi, an internal diaphragm opens and excess fuel pressure is routed back into the tank through the bottom of pressure regulator.
Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service. They do not require normal sched- uled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so.
FUEL LEVEL SENDING UNIT / SENSOR DESCRIPTION
The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a vari- able resistor track (card).
OPERATION
The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2
wires are used for electric fuel pump operation.For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit.
Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information.
For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be acti- vated if the fuel in the tank is more than approximately 85 percent of its rated capacity.
level
REMOVAL
The fuel level sending unit (fuel level sensor) and float assembly is located on the side of the fuel pump module (Fig. 3).
(1) Remove fuel pump module from fuel tank.
Refer to Fuel Pump Module Removal/Installation.
(2) To remove sending unit from pump module, lift on plastic locking tab (Fig. 4) while sliding sending unit tracks.
(3) Disconnect 4–wire electrical connector (Fig. 3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick / removal tool. Refer to Special Tools in 8W Wiring for tool part numbers.
Fig.3LOCATION-FUELGAUGESENDINGUNIT
1 - FUEL FILTER / FUEL PRESSURE REGULATOR 2 - FUEL PUMP MODULE ASSEMBLY 3 - 4-WAY ELEC. CONNECT. 4 - FLOAT ARM 5 - ELEC. FUEL PUMP 6 - INLET FILTER 7 - FUEL GAUGE SENDING UNIT 8 - GASKET (SEAL)
FUEL DELIVERY - GAS
14 - 8
FUEL LEVEL SENDING UNIT / SENSOR (Continued)DR
prevent the edge of the clamp from cutting into the hose. Only these rolled edge type clamps may be used in this system. All other types of clamps may cut into the hoses and cause high-pressure fuel leaks.
Use new original equipment type hose clamps.
QUICK CONNECT FITTING DESCRIPTION
Different types of quick-connect fittings are used to attach various fuel system components, lines and tubes. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Some may require the use of a spe- cial tool for disconnection and removal. Refer to Quick-Connect Fittings Removal/Installation for more information.
CAUTION: The interior components (o-rings, clips) of quick-connect fittings are not serviced sepa- rately, but new plastic spacers are available for some types. If service parts are not available, do not attempt to repair the damaged fitting or fuel line (tube). If repair is necessary, replace the complete fuel line (tube) assembly.
STANDARD PROCEDURE - QUICK-CONNECT FITTINGS
Also refer to Fuel Tubes/Lines/Hoses and Clamps. Different types of quick-connect fittings are used to attach various fuel system components, lines and tubes. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Safety latch clips are used on certain components/lines. Certain fittings may require use of a special tool for disconnection.
Fig.4FUELGAUGESENDINGUNIT-R/I
1 - SENDING UNIT 2 - LOCK TAB 3 - TRACKS 4 - NOTCH
INSTALLATION
(1) Connect necessary wiring into electrical con- nectors. Connect 4–wire electrical connector to pump module.
(2) Position sending unit to pump module. Slide
and snap into place.
(3) Install fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
FUEL LINES DESCRIPTION
Also refer to Quick-Connect Fittings.
DISCONNECTING
WARNING: THE FUEL SYSTEM MAY BE UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS, LINES, OR MOST COMPO- NENTS, FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRES- SURE RELEASE PROCEDURE.
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 contami- nated fuel in this system. If it is necessary to replace these lines/tubes/hoses, only those marked EFM/EFI may be used.
If equipped: The hose clamps used to secure rub- ber hoses on fuel injected vehicles are of a special rolled edge construction. This construction is used to
WARNING: THE FUEL SYSTEM IS UNDER A CON- STANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSE, FITTING OR LINE, FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO FUEL SYSTEM PRES- SURE RELEASE PROCEDURE.
CAUTION: The interior components (o-rings, spac- ers) of some types of quick-connect fitting are not serviced separately. If service parts are not avail- able, do not attempt to repair a damaged fitting or fuel If repair is necessary, replace complete fuel line assembly.
line.
(1) Perform fuel pressure release procedure. Refer
to Fuel Pressure Release Procedure.
DR QUICK CONNECT FITTING (Continued)
FUEL DELIVERY - GAS
14 - 9
(2) Disconnect negative battery cable from battery. (3) Clean fitting of any foreign material before dis-
assembly.
(4) 2–Button Type Fitting: This type of fitting is equipped with a push-button located on each side of quick-connect fitting (Fig. 5). Press on both buttons simultaneously for removal. Special tools are not required for disconnection.
Fig.6PINCHTYPEQUICK-CONNECTFITTING
1 - QUICK-CONNECT FITTINGS 2 - PINCH TABS
Fig.52-BUTTONTYPEFITTING
1 - QUICK-CONNECT FITTING 2 - PUSH-BUTTONS (2)
(5) Pinch-Type Fitting: This fitting is equipped with two finger tabs. Pinch both tabs together while removing fitting (Fig. 6). Special tools are not required for disconnection.
(6) Single-Tab Type Fitting: This type of fitting is equipped with a single pull tab (Fig. 7). The tab is removable. After tab is removed, quick-connect fitting can be separated from fuel system component. Spe- cial tools are not required for disconnection.
(a) Press release tab on side of fitting to release pull tab (Fig. 8). If release tab is not pressed prior to releasing pull tab, pull tab will be damaged.
(b) While pressing release tab on side of fitting,
use screwdriver to pry up pull tab (Fig. 8).
(c) Raise pull tab until it separates from quick-
connect fitting (Fig. 9). (7) Two-Tab Type Fitting: This type of fitting is equipped with tabs located on both sides of fitting (Fig. 10). The tabs are supplied for disconnecting quick-connect fitting from component being serviced. (a) To disconnect quick-connect fitting, squeeze plastic retainer tabs (Fig. 10) against sides of quick-connect fitting with your fingers. Tool use is
Fig.7SINGLE-TABTYPEFITTING
1 - PULL TAB 2 - QUICK-CONNECT FITTING 3 - PRESS HERE TO REMOVE PULL TAB 4 - INSERTED TUBE END
not required for removal and may damage plastic retainer.
(b) Pull
fitting from fuel system component
being serviced.
(c) The plastic retainer will remain on compo- nent being serviced after fitting is disconnected. The o-rings and spacer will remain in quick-con- nect fitting connector body.
FUEL DELIVERY - GAS
14 - 10
QUICK CONNECT FITTING (Continued)DR
Fig.8DISCONNECTINGSINGLE-TABTYPEFITTING 1 - PULL TAB 2 - SCREWDRIVER 3 - QUICK-CONNECT FITTING
Fig.10TYPICAL2–TABTYPEFITTING
1 - TAB(S) 2 - QUICK-CONNECT FITTING
Fig.9REMOVINGPULLTAB
1 - FUEL TUBE OR FUEL SYSTEM COMPONENT 2 - PULL TAB 3 - QUICK-CONNECT FITTING 4 - FUEL TUBE STOP
(8) Plastic Retainer Ring Type Fitting: This type of fitting can be identified by the use of a full- round plastic retainer ring (Fig. 11) usually black in color.
(a) To release fuel system component from quick- connect fitting, firmly push fitting towards compo- nent being serviced while firmly pushing plastic retainer ring into fitting (Fig. 11). With plastic ring depressed, pull fitting from component. The plas- tic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to discon- nect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in dis- connection.
Fig.11PLASTICRETAINERRINGTYPEFITTING
1 - FUEL TUBE 2 - QUICK CONNECT FITTING 3 - PUSH 4 - PLASTIC RETAINER 5 - PUSH 6 - PUSH 7 - PUSH 8 - PUSH
(b) After disconnection, plastic retainer ring will
remain with quick-connect fitting connector body.
(c) Inspect fitting connector body, plastic retainer for damage.
ring and fuel system component Replace as necessary. (9) Latch Clips: Depending on vehicle model and engine, 2 different types of safety latch clips are used
DR QUICK CONNECT FITTING (Continued)
FUEL DELIVERY - GAS
14 - 11
Fig.12LATCHCLIP-TYPE1
1 - TETHER STRAP 2 - FUEL LINE 3 - SCREWDRIVER 4 - LATCH CLIP 5 - FUEL RAIL
Fig.14FUELLINEDISCONNECTIONUSING
SPECIALTOOL
1 - SPECIAL FUEL LINE TOOL 2 - FUEL LINE 3 - FUEL RAIL
(c) Slide latch clip toward fuel rail while lifting
with screwdriver.
(d) Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (Fig. 14). Use tool to release locking fingers in end of line.
(e) With special tool still inserted, pull fuel line
from fuel rail.
(f) After disconnection, locking fingers will remain
within quick-connect fitting at end of fuel line. (10) Disconnect quick-connect fitting from fuel sys-
tem component being serviced.
CONNECTING
(1) Inspect quick-connect fitting body and fuel sys-
tem component for damage. Replace as necessary.
(2) Prior to connecting quick-connect
fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil.
(3) Insert quick-connect fitting into fuel tube or fuel system component until built-on stop on fuel tube or component rests against back of fitting.
(4) Continue pushing until a click is felt. (5) Single-tab type fitting: Push new tab down
until it locks into place in quick-connect fitting.
(6) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.).
(7) Latch Clip Equipped: Install latch clip (snaps into position). If latch clip will not fit, this indi- cates fuel line is not properly installed to fuel rail (or other fuel line). Recheck fuel line con- nection.
(8) Connect negative cable to battery. (9) Start engine and check for leaks.
Fig.13LATCHCLIP-TYPE2
1 - LATCH CLIP
(Fig. 12) or (Fig. 13). Type-1 is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/fuel rail connection, or to join fuel lines together.
(a) Type 1: Pry up on latch clip with a screw-
driver (Fig. 12).
(b) Type 2: Separate and unlatch 2 small arms on end of clip (Fig. 13) and swing away from fuel line.
14 - 12
FUEL DELIVERY - GAS
DR
BEFORE SERVICING THE FUEL PUMP MODULE, THE FUEL SYSTEM PRESSURE MUST BE RELEASED.
(1) Drain and remove fuel tank. Refer to Fuel
Tank Removal/Installation.
(2) The plastic fuel pump module locknut (Fig. 15) is threaded onto fuel tank. Install Special Tool 6856
to locknut and remove locknut (Fig. 16). The fuel pump module will spring up slightly when locknut is removed.(3) Remove module from fuel tank.
FUEL PUMP DESCRIPTION
The electric fuel pump is located inside of the fuel pump module. A 12 volt, permanent magnet, electric motor powers the fuel pump. The electric fuel pump is not a separate, serviceable component.
OPERATION
Voltage to operate the electric pump is supplied
through the fuel pump relay.
Fuel is drawn in through a filter at the bottom of the module and pushed through the electric motor gearset to the pump outlet.
Check Valve Operation: The bottom section of the fuel pump module contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line injectors. Fuel between the check valve and fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. The electric fuel pump is not a separate, service-
able component.
FUEL PUMP MODULE DESCRIPTION
The fuel pump module assembly is located on the top of the fuel tank (Fig. 1). The complete assembly contains the following components: † A combination fuel filter/fuel pressure regulator † A separate fuel pick-up, or inlet filter † An electric fuel pump † A lockring to retain pump module to tank † A soft gasket between tank flange and module † A fuel gauge sending unit (fuel level sensor) † Fuel line connection The fuel gauge sending unit may be serviced sepa- rately. If the electrical fuel pump, primary inlet filter, fuel filter or fuel pressure regulator require service, the fuel pump module must be replaced.
OPERATION
Refer to Fuel Pump, Inlet Filter, Fuel Filter / Fuel
Pressure Regulator and Fuel Gauge Sending Unit.
REMOVAL
Fig.15FUELPUMPMODULE(TOP)
1 - FUEL FILTER / FUEL PRESSURE REGULATOR 2 - ALIGNMENT ARROW 3 - TOP OF PUMP MODULE 4 - LOCKNUT 5 - ALIGNMENT MARKS
Fig.16LOCKNUTREMOVAL/INSTALLATION-
TYPICAL
WARNING: THE FUEL SYSTEM IS UNDER A CON- STANT PRESSURE (EVEN WITH THE ENGINE OFF).
1 - SPECIAL TOOL 6856
2 - LOCKNUTDR FUEL PUMP MODULE (Continued) INSTALLATION
CAUTION: Whenever the fuel pump module is ser- viced, the rubber gasket must be replaced.
(1) Using a new gasket, position fuel pump module
into opening in fuel tank.
(2) Position locknut over top of fuel pump module.
Install locknut finger tight.
(3) Rotate module until embossed alignment arrow (Fig. 15) points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fitting on fuel filter/ fuel pressure regulator is pointed to drivers side of vehicle.
(4) Install Special Tool 6856 (Fig. 16) to locknut. (5) Tighten locknut. Refer to Torque Specifications. (6) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
FUEL RAIL DESCRIPTION
The fuel injector rail is used to mount the fuel
injectors to the engine.
OPERATION
High pressure from the fuel pump is routed to the fuel rail. The fuel rail then supplies the necessary fuel to each individual fuel injector.
A quick-connect fitting with a safety latch clip is
used to attach the fuel line to the fuel rail.
The fuel rail is not repairable.
CAUTION: The left and right sections of the fuel rail are connected with either a flexible connecting hose, or joints. Do not attempt to separate the rail halves at these connecting hose or joints. Due to the design of the connecting hose or joint, it does not use any clamps. Never attempt to install a clamping device of any kind to the hose or joint. When removing the fuel rail assembly for any rea- son, be careful not to bend or kink the connecting hose or joint.
REMOVAL
3.7L V-6
WARNING: THE FUEL SYSTEM IS UNDER CON- STANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING FUEL RAIL, FUEL SYSTEM PRESSURE MUST BE RELEASED.
FUEL DELIVERY - GAS
14 - 13
CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connector tubes (Fig. 18). Due to design of tubes, it does not use any clamps. Never attempt to install a clamping device of any kind to tubes. When removing fuel rail assembly for any reason, be careful not to bend or kink tubes.
(1) Remove fuel tank filler tube cap. (2) Perform Fuel System Pressure Release Proce-
dure.
body.
(3) Remove negative battery cable at battery. (4) Remove air duct at throttle body air box. (5) Remove air box at throttle body. (6) Remove air resonator mounting bracket at
front of throttle body (2 bolts).
(7) Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection. Refer to Quick-Connect Fittings.
(8) Remove necessary vacuum lines at
throttle
(9) Disconnect electrical connectors at all 6 fuel injectors. To remove connector refer to (Fig. 17). Push red colored slider away from injector (1). While push- ing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring har- ness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.
(10) Disconnect electrical connectors at all throttle
body sensors.
Removal/Installation.
(11) Remove 6 ignition coils. Refer to Ignition Coil
(12) Remove 4 fuel rail mounting bolts (Fig. 18). (13) Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes.
(14) Remove fuel rail
(with injectors attached)
from engine.
(15) If fuel injectors are to be removed, refer to
Fuel Injector Removal/Installation.
4.7L V-8
WARNING: THE FUEL SYSTEM IS UNDER CON- STANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING FUEL RAIL, FUEL SYSTEM PRESSURE MUST BE RELEASED.
FUEL DELIVERY - GAS
14 - 14
FUEL RAIL (Continued)DR
CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connector tubes (Fig. 19). Due to design of tubes, it does not use any clamps. Never attempt to install a clamping device of any kind to tubes. When removing fuel rail assembly for any reason, be careful not to bend or kink tubes.
Fig.17REMOVE/INSTALLINJECTORCONNECTOR
(1) Remove fuel tank filler tube cap. (2) Perform Fuel System Pressure Release Proce-
dure.
body.
(3) Remove negative battery cable at battery. (4) Remove air duct at throttle body air box. (5) Remove air box at throttle body. (6) Remove air resonator mounting bracket at
front of throttle body (2 bolts).
(7) Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection. Refer to Quick-Connect Fittings.
(8) Remove necessary vacuum lines at
throttle
(9) Disconnect electrical connectors at all 8 fuel injectors. To remove connector refer to (Fig. 17). Push red colored slider away from injector (1). While push- ing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring har- ness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.
(10) Disconnect electrical connectors at all throttle
body sensors.
Removal/Installation.
(11) Remove 8 ignition coils. Refer to Ignition Coil
(12) Remove 4 fuel rail mounting bolts (Fig. 19). (13) Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes.
(14) Remove fuel rail
(with injectors attached)
from engine.
(15) If fuel injectors are to be removed, refer to
Fuel Injector Removal/Installation.
Fig.18FUELRAILREMOVE/INSTALL-3.7LV-6
5.7L V-8
1 - MOUNTING BOLTS (4) 2 - QUICK-CONNECT FITTING 3 - FUEL RAIL 4 - INJ. #1
5 - INJ. #3
6 - INJ. #5
7 - INJ. #2
8 - INJ. #4
9 - INJ. #6
10 - CONNECTOR TUBEWARNING: THE FUEL SYSTEM IS UNDER CON- STANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING FUEL RAIL, FUEL SYSTEM PRESSURE MUST BE RELEASED.
DR FUEL RAIL (Continued)
FUEL DELIVERY - GAS
14 - 15
cable routing tray. Note original cable positions while removing (Fig. 22).
(7) Remove spark plug cable tray from engine by releasing 4 retaining clips (Fig. 21). Remove tray and cables from engine as an assembly.
(8) Disconnect electrical connectors at all 8 igni- tion coils. Refer to Ignition Coil Removal/Installation. (9) Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection. Refer to Quick-Connect Fittings.
(10) Disconnect electrical connectors at all 8 fuel injectors. To remove connector refer to (Fig. 17). Push red colored slider away from injector (1). While push- ing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring har- ness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.
(11) Disconnect electrical connectors at all throttle
body sensors.
own clamps (Fig. 20).
(12) Remove 4 fuel rail mounting bolts and hold-
(13) Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in intake manifold. Gently rock and pull right side of rail until injectors just start to clear intake manifold head holes. Repeat this procedure (left/right) until all injectors have cleared machined holes.
(14) Remove fuel rail
(with injectors attached)
from engine.
(15) If fuel injectors are to be removed, refer to
Fuel Injector Removal/Installation.
5.9L V-8
WARNING: THE FUEL SYSTEM IS UNDER A CON- STANT PRESSURE (EVEN WITH ENGINE TURNED OFF). BEFORE SERVICING FUEL RAIL ASSEMBLY, FUEL SYSTEM PRESSURE MUST BE RELEASED.
To release fuel pressure, refer to Fuel System Pres-
sure 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. 24). 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.
(1) Remove negative battery cable at battery. (2) Remove air cleaner. (3) Perform fuel pressure release procedure. (4) Remove throttle body from intake manifold.
Refer to Throttle Body Removal/Installation.
Fig.19FUELRAILREMOVE/INSTALL-4.7LV-8
1 - MOUNTING BOLTS (4) 2 - INJ.#7
3 - INJ.#5
4 - QUICK-CONNECT FITTING 5 - INJ.#3
6 - FUEL INJECTOR RAIL 7 - INJ.#1
8 - CONNECTOR TUBE 9 - INJ.#2
10 - INJ.#4
11 - INJ.#6
12 - INJ.#8
13 - PRESSURE TEST PORT CAPCAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connector tube (Fig. 20). Due to design of tube, it does not use any clamps. Never attempt to install a clamping device of any kind to tube. When removing fuel rail assembly for any reason, be care- ful not to bend or kink tube.
(1) Remove fuel tank filler tube cap. (2) Perform Fuel System Pressure Release Proce-
dure.
engine).
(3) Remove negative battery cable at battery. (4) Remove flex tube (air
cleaner housing to
(5) Remove air resonator box at throttle body. (6) Disconnect all spark plug cables from all spark plugs and ignition coils. Do not remove cables from
FUEL DELIVERY - GAS
14 - 16
FUEL RAIL (Continued)DR
(6) Disconnect electrical connectors at all
fuel injectors. To remove connector refer to (Fig. 17). Push red colored slider away from injector (1). While push- ing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring har- ness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.
(7) Disconnect fuel tube (line) at side of fuel rail.
Refer to Quick-Connect Fittings for procedures,
(8) Remove the remaining fuel rail mounting bolts. (9) Gently rock and pull the left fuel rail until the fuel injectors just start to clear the intake manifold. Gently rock and pull the right fuel rail until the fuel injectors just start to clear the intake manifold. Repeat this procedure (left/right) until all fuel injec- tors have cleared the intake manifold.
(10) Remove fuel rail
(with injectors attached)
from engine.
Fig.205.7LFUELRAIL
1 - FUEL RAIL 2 - MOUNTING BOLT 3 - HOLDOWN CLAMPS 4 - CONNECTOR TUBE
8.0L V-10
WARNING: THE FUEL SYSTEM IS UNDER A CON- STANT PRESSURE EVEN WITH THE ENGINE OFF. BEFORE SERVICING FUEL RAIL, FUEL SYSTEM PRESSURE MUST BE RELEASED.
(1) Remove negative battery cable at battery. (2) Remove air cleaner housing and tube. (3) Perform fuel pressure release procedure. Refer
to Fuel Delivery System section of this group.
(4) Disconnect throttle body linkage and remove throttle body from intake manifold. Refer to Throttle Body removal in this group.
(5) Remove ignition coil pack and bracket assem- bly (Fig. 25) at intake manifold and right engine valve cover (four bolts).
(6) Remove upper half of intake manifold. Refer to
Engines for procedures.
(7) Disconnect electrical connectors at all
fuel injectors. To remove connector refer to (Fig. 26). Push red colored slider away from injector (1). While push- ing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring har- ness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification.
(8) Disconnect fuel
line quick-connect fitting at left-rear end of fuel rail. A special 3/8 inch fuel line disconnection tool will be necessary.
(9) Remove the six fuel rail mounting bolts from
the lower half of intake manifold (Fig. 27).
(10) 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 right fuel rail until the fuel injectors just start to clear the intake mani- fold. Repeat this procedure (left/right) until all fuel injectors have cleared the intake manifold.
Fig.215.7LSPARKPLUGCABLEROUTINGTRAY 1 - SPARK PLUG CABLES 2 - RETAINING CLIP 3 - SPARK PLUG CABLE ROUTING TRAY
(5) If equipped with air conditioning, remove the A-shaped A/C compressor-to-intake manifold support bracket (three bolts) (Fig. 23).
DR FUEL RAIL (Continued)
FUEL DELIVERY - GAS
14 - 17
Fig.225.7LSPARKPLUGCABLEROUTING
1 - #8 COIL-TO- #5 SPARK PLUG (MARKED 5/8) 2 - #5 COIL-TO- #8 SPARK PLUG (MARKED 5/8) 3 - #7 COIL-TO- #4 SPARK PLUG (MARKED 4/7) 4 - #3 COIL-TO- #2 SPARK PLUG (MARKED 2/3) 5 - #1 COIL-TO- #6 SPARK PLUG (MARKED 1/6) 6 - CLIPS (TRAY-TO-MANIFOLD RETENTION)
7 - CABLE TRAY 8 - CLIPS (SPARK PLUG CABLE-TO-TRAY- RETENTION) 9 - #2 COIL-TO- #3 SPARK PLUG (MARKED 2/3) 10 - #6 COIL-TO- #1 SPARK PLUG (MARKED 1/6) 11 - #4 COIL-TO- #7 SPARK PLUG (MARKED 4/7)
Fig.23A/CCOMPRESSORSUPPORTBRACKET-
5.9LV-8
1 - AIR CONDITIONING COMPRESSOR SUPPORT BRACKET 2 - MOUNTING BOLTS
(11) Remove fuel rail
(with injectors attached)
from engine.
(12) If fuel injectors are to be removed, refer to
Fuel Injector Removal/Installation.
Fig.24FUELRAILREMOVE/INSTALL-5.9LV-8
1 - FUEL RAIL CONNECTING HOSE 2 - FUEL RAIL 3 - MOUNTING BOLTS (4)
FUEL DELIVERY - GAS
14 - 18
FUEL RAIL (Continued)DR
Fig.25IGNITIONCOILPACKANDMOUNTING
BRACKET-8.0LV-10
1 - COIL PACKS AND BRACKET 2 - MOUNTING BOLTS (4)
Fig.27FUELRAILMOUNTINGBOLTS-8.0LV-10-
TYPICAL
1 - FUEL RAIL 2 - ELECTRICAL CONNECTOR 3 - MOUNTING BOLTS (6) 4 - INTAKE MANIFOLD LOWER HALF 5 - FUEL PRESSURE TEST PORT 6 - FUEL INJECTORS (10)
INSTALLATION
3.7L V-6
(1) If fuel injectors are to be installed, refer to Fuel
Injector Removal/Installation.
fuel
injector machined bores in
(2) Clean out intake manifold.
(3) Apply a small amount of engine oil to each fuel injector o-ring. This will help in fuel rail installation. injector assembly to
(4) Position fuel
rail/fuel
machined injector openings in cylinder head.
(5) Guide each injector into cylinder head. Be care-
ful not to tear injector o-rings.
(6) Push right side of fuel rail down until fuel injectors have bottomed on cylinder head shoulder. Push left fuel rail down until injectors have bot- tomed on cylinder head shoulder.
(7) Install 4 fuel rail mounting bolts and tighten.
Refer to torque specifications.
(8) Install 6 ignition coils. Refer to Ignition Coil
Removal/Installation.
(9) Connect electrical connectors to throttle body. (10) Connect electrical connectors at all fuel injec- tors. To install connector, refer to (Fig. 17). Push con- nector onto injector (1) and then push and lock red colored slider (2). Verify connector is locked to injec- tor by lightly tugging on connector.
Fig.26REMOVE/INSTALLFUELINJECTOR
CONNECTOR
DR FUEL RAIL (Continued)
FUEL DELIVERY - GAS
14 - 19
(11) Connect necessary vacuum lines to throttle
