Dodge Ram Truck 1500-2500-3500. Manual — part 1460

5.7L V-8

1. If fuel injectors are to be installed, (Refer to 14 -

FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - INSTALLATION).

2. Clean out fuel injector machined bores in intake

manifold.

3. Apply a small amount of engine oil to each fuel

injector o-ring. This will help in fuel rail installation.

4. Position fuel rail/fuel injector assembly to machined

injector openings in intake manifold.

5. Guide each injector into intake manifold. Be careful

not to tear injector o-rings.

6. Push right side of fuel rail down until fuel injectors

have bottomed on shoulders. Push left fuel rail
down until injectors have bottomed on shoulders.

7. Install 4 fuel rail holdown clamps and 4 mounting

bolts. (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - SPECIFICATIONS)

8. Position spark plug cable tray and cable assembly

to intake manifold. Snap 4 cable tray retaining clips
into intake manifold.

9. Install all cables to spark plugs and ignition coils.

10. Connect electrical connector to throttle body.

11. Install electrical connectors to all 8 ignition coils.

(Refer to 8 - ELECTRICAL/IGNITION CONTROL/IGNITION COIL - INSTALLATION)

12. Connect electrical connector to throttle body.

13. Connect electrical connectors at all fuel injectors. To install connector, refer to. Push connector onto injector (1)

and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging on con-
nector.

14. Connect fuel line latch clip and fuel line to fuel rail. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK

CONNECT FITTING - STANDARD PROCEDURE)

15. Install air resonator to throttle body (2 bolts).

16. Install flexible air duct to air box.

17. Connect battery cable to battery.

18. Start engine and check for leaks.

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FUEL DELIVERY - GAS

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4.7L V-8

1. If fuel injectors are to be installed, (Refer to 14 -

FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - INSTALLATION).

2. Clean out fuel injector machined bores in intake

manifold.

3. Apply a small amount of engine oil to each fuel

injector o-ring. This will help in fuel rail installation.

4. Position fuel rail/fuel injector assembly to machined

injector openings in cylinder head.

5. Guide each injector into cylinder head. Be careful

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 bottomed on
cylinder head shoulder.

7. Install 4 fuel rail mounting bolts and tighten. (Refer

to 14 - FUEL SYSTEM/FUEL DELIVERY - SPECI-
FICATIONS)

8. Install 8 ignition coils. (Refer to 8 - ELECTRICAL/

IGNITION CONTROL/IGNITION COIL - INSTALLA-
TION)

9. Connect electrical connectors to throttle body.

10. Connect electrical connectors at all fuel injectors.

To install connector, refer to. Push connector onto
injector (1) and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging
on connector.

11. Connect necessary vacuum lines to throttle body.

12. Install air resonator mounting bracket near front of throttle body (2 bolts).

13. Connect fuel line latch clip and fuel line to fuel rail. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK

CONNECT FITTING - STANDARD PROCEDURE)

14. Install air box to throttle body.

15. Install air duct to air box.

16. Connect battery cable to battery.

17. Start engine and check for leaks.

8.3L - SRT-10

1. Install the fuel injectors to the fuel rail.

2. Install fuel rail under throttle body.

3. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.

4. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to

12 N·m (105 in. lbs.).

5. Attach electrical connectors to fuel injectors.

6. Connect the electrical connector to the MAP sensor and Coolant Temperature sensor.

7. Connect the electrical connector to the TPS and Idle Air Control.

8. Install the wiring harness to the wiring clips under the throttle body.

9. Connect fuel supply tube to fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery section

10. Install the negative battery cable.

11. Install the air cleaner assembly, refer to the Engine/Air Intake System/Air Cleaner Housing for more information.

12. Use the DRBIII

T

scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.

DR/DH

FUEL DELIVERY - GAS

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TANK - FUEL

DESCRIPTION

The fuel tank is constructed of a plastic material. Its main functions are for fuel storage and for placement of the fuel
pump module, and (if equipped) certain ORVR components.

OPERATION

All models pass a full 360 degree rollover test without fuel leakage. To accomplish this, fuel and vapor flow controls
are required for all fuel tank connections.

Two check (control) valves are mounted into the top of the fuel tank. Refer to Fuel Tank Check Valve for additional
information.

An evaporation control system is connected to the fuel tank to reduce emissions of fuel vapors into the atmosphere.
When fuel evaporates from the fuel tank, vapors pass through vent hoses or tubes to a charcoal canister where
they are temporarily held. When the engine is running, the vapors are drawn into the intake manifold. Certain mod-
els are also equipped with a self-diagnosing system using a Leak Detection Pump (LDP) or NVLD Pump, and/or an
On-Board Refueling Vapor Recovery (ORVR) system. Refer to Emission Control System for additional information.

REMOVAL- EXCEPT DIESEL

Fuel Tank Draining

WARNING: THE FUEL SYSTEM MAY BE UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. THIS PRESSURE MUST BE RELEASED BEFORE SERVICING FUEL TANK.

Two different procedures may be used to drain fuel tank: through the fuel fill fitting on tank, or using a diagnostic
scan tool to activate the fuel pump relay. Due to a one-way check valve installed into the fuel fill opening fitting at
the tank, the tank cannot be drained conventionally at the fill cap.

The quickest draining procedure involves removing the rubber fuel fill hose.

As an alternative procedure, the electric fuel pump may be activated allowing tank to be drained at fuel rail con-
nection. Refer to diagnostic scan tool for fuel pump activation procedures. Before disconnecting fuel line at fuel rail,
release fuel pressure. Refer to the Fuel System Pressure Release Procedure for procedures. Attach end of special
test hose tool number 6541, 6539, 6631 or 6923 at fuel rail disconnection (tool number will depend on model and/or
engine application). Position opposite end of this hose tool to an approved gasoline draining station. Activate fuel
pump and drain tank until empty.

If electric fuel pump is not operating, fuel must be drained through fuel fill fitting at tank. Refer to following proce-
dures.

1. Release fuel system pressure.

2. Raise vehicle.

3. Thoroughly clean area around fuel fill fitting and rubber fuel fill hose at tank.

4. If vehicle is equipped with 4 doors and a 6 foot (short) box, remove left-rear tire/wheel.

5. Loosen clamp and disconnect rubber fuel fill hose at tank fitting. Using an approved gas holding tank, drain fuel

tank through this fitting.

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Tank Removal

1. Disconnect and separate fuel vent line (1) from fuel fill bezel (2).

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