Dodge Ram Truck 1500-2500-3500. Manual — part 1478

not enter the injection pump is directed to the overflow valve. The overflow valve regulates how much excess fuel
is used for lubrication of the pump and how much is returned to the tank through the drain manifold.

Fuel entering the injection pump is pressurized to between 300-1600 bar (4351-23,206 psi) by three radial pumping
chambers. The pressurized fuel is then supplied to the fuel rail.

WARNING: HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION PUMP TO THE FUEL INJECTORS. THIS MAY BE AS HIGH AS 160,000 KPA (23,206 PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-PRESSURE FUEL LEAKS. INSPECT FOR HIGH-PRES-
SURE FUEL LEAKS WITH A SHEET OF CARDBOARD. HIGH FUEL INJECTION PRESSURE CAN CAUSE PER-
SONAL INJURY IF CONTACT IS MADE WITH THE SKIN.

Certain fuel system components can be found in.

CUMMINS FUEL SYSTEM COMPONENTS

1 - ENGINE COOLANT TEMPERATURE (ECT) SENSOR

14 - FUEL DRAIN TUBE

2 - INTAKE MANIFOLD AIR HEATER/ELEMENTS

15 - OIL PRESSURE SWITCH

3 - FUEL PRESSURE SENSOR

16 - ENGINE CONTROL MODULE (ECM)

4 - FUEL PRESSURE LIMITING VALVE

17 - FUEL INJECTION PUMP

5 - HIGH-PRESSURE FUEL LINES

18 - CRANKSHAFT POSITION (ENGINE SPEED) SENSOR

6 - FUEL HEATER

19 - CAMSHAFT POSITION SENSOR (CMP)

7 - HIGH-PRESSURE FUEL RAIL

20 - FUEL CONTROL ACTUATOR (FCA)

8 - FUEL HEATER TEMPERATURE SENSOR (THERMOSTAT)

21 - CASCADE OVERFLOW VALVE

9 - FUEL FILTER/WATER SEPARATOR
10 - FUEL DRAIN MANIFOLD (CYLINDER HEAD FUEL RETURN
LINE)
11 - DRAIN VALVE
12 - FUEL RETURN LINE CONNECTION (TO FUEL TANK)
13 - FUEL SUPPLY LINE (LOW-PRESSURE, TO ENGINE)

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FUEL DELIVERY - DIESEL

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STANDARD PROCEDURE

STANDARD PROCEDURES - WATER DRAINING AT FUEL FILTER

Refer to Fuel Filter/Water Separator removal/installation for procedures.

STANDARD PROCEDURES - CLEANING FUEL SYSTEM PARTS

CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system compo-
nents. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight
tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging
of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any
fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after
disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if nec-
essary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.

STANDARD PROCEDURE - FUEL SYSTEM PRIMING

A certain amount of air becomes trapped in the fuel system when fuel system components on the supply and/or
high-pressure side are serviced or replaced. Fuel system priming is accomplished using the electric fuel transfer (lift)
pump.

Servicing or replacing fuel system components will not require fuel system priming.

The fuel transfer (lift) pump is self-priming: When the key is first turned on (without cranking engine), the pump
operates for approximately 1 to 2 second and then shuts off (Note: When ambient temperatures are cold enough to
cause the intake air heaters to operate, the fuel lift pump will operate during the entire intake air pre-heat cycle).
The pump will also operate for up to 25 seconds after the starter is quickly engaged, and then disengaged without
allowing the engine to start. The pump shuts off immediately if the key is on and the engine stops running.

1. Turn key to CRANK position and quickly release key to ON position before engine starts. This will operate fuel

transfer pump for approximately 25 seconds.

2. Crank engine. If the engine does not start after 25 seconds, turn key to OFF position, and leave it off for at least

5 seconds. Repeat previous step until engine starts.

3. Fuel system priming is now completed.

4. Attempt to start engine. If engine will not start, proceed to following steps. When engine does start, it may run

erratically and be noisy for a few minutes. This is a normal condition.

CAUTION: Do not engage the starter motor for more than 30 seconds at a time. Allow two minutes between
cranking intervals.

5. Perform previous fuel priming procedure steps using fuel transfer pump. Be sure fuel is present at fuel tank.

6. Crank the engine for 30 seconds at a time to allow fuel system to prime.

WARNING: THE FUEL INJECTION PUMP SUPPLIES EXTREMELY HIGH FUEL PRESSURE TO EACH INDIVID-
UAL INJECTOR THROUGH THE HIGH-PRESSURE LINES. FUEL UNDER THIS AMOUNT OF PRESSURE CAN
PENETRATE THE SKIN AND CAUSE PERSONAL INJURY. WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING. DO NOT LOOSEN FUEL FITTINGS WHILE ENGINE IS RUNNING.

WARNING: ENGINE MAY START WHILE CRANKING STARTER MOTOR.

SPECIFICATIONS

FUEL INJECTOR FIRING ORDER - DIESEL

1–5–3–6–2–4

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FUEL DELIVERY - DIESEL

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TORQUE - FUEL SYSTEM - DIESEL ENGINE

DESCRIPTION

N-m

Ft. Lbs.

In. Lbs.

Crankshaft Position Sensor

9

80

Camshaft Position Sensor

9

-

80

Engine Coolant Temperature Sensor

18

13

160

Rear Engine Lift Bracket Bolts

77

56

-

Fuel Connector Nut at Cylinder Head

50

37

-

Fuel Filler Hose Clamp at Tank

3

-

27

Fuel Filler Housing-to-Body Screws

2

-

17

Fuel Filter Lid

34

25

-

Fuel Filter Drain Valve Screws

1.5

-

14

Fuel Heater Element Screws

1.5

-

14

Fuel Line Banjo Fitting Bolts

24

18

-

Fuel Line Banjo Fitting Bolts at Fuel Filter Housing

24

18

-

Fuel Line Fittings (High-Pressure - Pump to Rail)

37

27

-

Fuel Line Fittings (High-Pressure - Cylinder head

to Rail)

30

22

-

#6 Fuel Line Shield Bolts

43

32

-

Fuel Injector Solenoid Nuts

1.25

-

11

Fuel Injection Pump-to-Gear Shaft Nut

105

77

-

Fuel Injection Pump Mounting Nuts

24

18

-

Fuel Line Brace-to-Intake manifold cover bolt

(High-Pressure)

24

18

-

Fuel Pressure Sensor

70

52

-

Fuel Pressure Limiting Valve (Banjo Bolt)

24

18

-

Fuel Pressure Limiting Valve (In Fuel Rail)

70

52

-

Fuel Rail Mounting Bolts

24

18

212

Fuel Tank Mounting Straps

41

30

-

Map Sensor Mounting Screws

1

-

9

ECM-to-Engine Bracket Mounting Bolts

24

18

-

ECM Electrical Harness Connector

3

-

27

Water-In-Fuel Sensor

4.5

-

39

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FUEL DELIVERY - DIESEL

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SPECIAL TOOLS

DIESEL FUEL SYSTEM

FUEL PRESSURE TEST ADAPTER - # 9012

FUEL PRESSURE TEST ADAPTER - #9014

FUEL INJECTOR REMOVER - #9010

PRESSURE CAP - #9011

FUEL PRESSURE TEST ADAPTER - #9013

FUEL INJECTOR TUBE (CONNECTOR) REMOVER -

#9015

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FUEL DELIVERY - DIESEL

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