Dodge Ram Truck 1500-2500-3500. Manual — part 1477
4.7L V-8
The throttle shaft end of throttle body (5) slides into a
socket in TPS. The TPS must be installed so that it
can be rotated a few degrees. If sensor will not rotate,
install sensor with throttle shaft on other side of socket
tangs. The TPS will be under slight tension when
rotated.
1. Install TPS and two retaining bolts.
2. Tighten bolts to 7 N·m (60 in. lbs.) torque.
3. Manually operate throttle control lever by hand to
check for any binding of TPS.
4. Connect TPS electrical connector to TPS.
5. Install air duct/air box to throttle body.
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FUEL INJECTION - GAS
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8.3L - SRT-10
The TPS is attached to the throttle body.
The throttle shaft end of the throttle body slides into a
socket in the TPS. When indexed correctly, the TPS
can rotate a few degrees to line up the mounting
screw holes with the screw holes in the throttle body.
If the sensor will not rotate into place, install the sen-
sor with the throttle shaft on the other side of the
socket tangs. The TPS has slight tension when rotated
to align the mounting holes.
1. Install TPS and mounting screws.
2. Attach electrical connector to the TPS.
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FUEL INJECTION - GAS
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FUEL DELIVERY - DIESEL
TABLE OF CONTENTS
page
page
FUEL DELIVERY - DIESEL
DESCRIPTION - DIESEL FUEL SYSTEM
DRAINING AT FUEL FILTER . . . . . . . . . . . . . 101
STANDARD PROCEDURES - CLEANING
FUEL SYSTEM PARTS . . . . . . . . . . . . . . . . . 101
STANDARD PROCEDURE - FUEL SYSTEM
PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
FUEL INJECTOR FIRING ORDER - DIESEL
TORQUE - FUEL SYSTEM - DIESEL ENGINE
. . . . . . . . . . . . . . . . 103
FILTER - FUEL / WATER SEPARATOR
. . . . . . . . . . . . . . . . . . . . . . . . 105
. . . . . . . . . . . . . . . . . . . . . . . . . . 105
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
. . . . . . . . . . . . . . . . . . . . . . . . 107
HEATER-FUEL
. . . . . . . . . . . . . . . . . . . . . . . . 108
. . . . . . . . . . . . . . . . . . . . . . . . . . 108
DIAGNOSIS AND TESTING - FUEL HEATER
. . . . . . . . . . . . . . 109
RELAY - FUEL HEATER
. . . . . . . . . . . . . . . . . . . . . . . . 109
. . . . . . . . . . . . . . . . . . . . . . . . . . 109
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
. . . . . . . . . . . . . . . . . . . . . . . . 110
PUMP - FUEL INJECTION
. . . . . . . . . . . . . . . . . . . . . . . . 110
. . . . . . . . . . . . . . . . . . . . . . . . . . 110
DIAGNOSIS AND TESTING - FUEL INJECTION
. . . . . . . . . . . . . . . . . . . . . . . 110
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
. . . . . . . . . . . . . . . . . . . . . . . . 113
SENSOR - FUEL LEVEL SENDING UNIT
. . . . . . . . . . . . . . . . . . . . . . . . 114
. . . . . . . . . . . . . . . . . . . . . . . . . . 114
. . . . . . . . . . . . . . 115
LINES - FUEL
. . . . . . . . . . . . . . . . . . . . . . . . 115
. . . . . . . . . . . . . . . . . . . . . . . . . . 115
DIAGNOSIS AND TESTING - HIGH-PRESSURE
. . . . . . . . . . . . . . . . . . . . 115
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
. . . . . . . . . . . . . . . . . . . . . . . . 117
SENSOR - FUEL PRESSURE
. . . . . . . . . . . . . . . . . . . . . . . . 118
. . . . . . . . . . . . . . . . . . . . . . . . . . 118
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
. . . . . . . . . . . . . . . . . . . . . . . . 119
VALVE - FUEL PRESSURE LIMITING
. . . . . . . . . . . . . . . . . . . . . . . . 119
. . . . . . . . . . . . . . . . . . . . . . . . . . 119
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
. . . . . . . . . . . . . . . . . . . . . . . . 119
TANK - FUEL
. . . . . . . . . . . . . . . . . 120
. . . . . . . . . . . . . . . . . . . . 120
. . . . . . . . . . . . . . . . . 121
MODULE - FUEL TANK
. . . . . . . . . . . . . . . . . . . . . . . . 121
. . . . . . . . . . . . . . . . . . . . . . . . . . 121
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
. . . . . . . . . . . . . . . . . . . . . . . . 122
PUMP - FUEL TRANSFER
. . . . . . . . . . . . . . . . . . . . . . . . 122
. . . . . . . . . . . . . . . . . . . . . . . . . . 122
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
. . . . . . . . . . . . . . . . . . . . . . . . 123
VALVE - CASCADE OVERFLOW
. . . . . . . . . . . . . . . . . . . . . . . . 123
. . . . . . . . . . . . . . . . . . . . . . . . . . 123
. . . . . . . . . . . . . . 124
SENSOR-WATER IN FUEL
. . . . . . . . . . . . . . . . . . . . . . . . 124
. . . . . . . . . . . . . . . . . . . . . . . . . . 124
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
CIRCUIT - FUEL DRAIN
. . . . . . . . . . . . . . . . . . . . . . . . . . 124
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FUEL DELIVERY - DIESEL
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FUEL DELIVERY - DIESEL
DESCRIPTION - DIESEL FUEL SYSTEM
The fuel system used on the Cummins engine is an electronically controlled, Bosch HPCR (High-Pressure Common
Rail) system. The HPCR system consists of five main components:
•
Electric Fuel Transfer (lift) Pump Located in the Fuel Tank
•
Fuel Pump/Gear Pump (attached to fuel injection pump)
•
High-Pressure Fuel Injection Pump
•
Fuel Injection Rail
•
Fuel Injectors
Also to be considered as part of the overall fuel system are:
•
Accelerator Pedal
•
Air Cleaner Housing/Element
•
Check Valve Banjo Fitting at Rear of Cylinder Head
•
Fuel Connector Tubes
•
Fuel Drain Manifold (passage)
•
Fuel Drain Valve (at filter)
•
Fuel Filter/Water Separator
•
Fuel Heater
•
Fuel Heater Relay
•
Fuel Transfer Pump Relay
•
Fuel Level (gauge) Sending Unit
•
Fuel Pressure Limiting Valve
•
Fuel Tank
•
Fuel Tank Module (containing a fuel gauge sending unit, separate fuel filter located at bottom of tank module,
and fuel transfer pump)
•
Fuel Tank Filler/Vent Tube Assembly
•
Fuel Tank Filler Tube Cap
•
Fuel Tubes/Lines/Hoses
•
High-Pressure Fuel Injector Lines
•
In-Tank Fuel Filter (at bottom of fuel tank module)
•
Low-Pressure Fuel Supply Lines
•
Low-Pressure Fuel Return Line
•
Overflow Valve
•
Quick-Connect Fuel Line Fittings
•
Accelerator Pedal Position Sensor (APPS) Located in Cab
•
Water Draining (maintenance)
•
Water-In-Fuel (WIF) Sensor
The fuel injection pump supplies high pressure to the fuel rail independent of engine speed. This high pressure fuel
is then accumulated in the fuel rail. High pressure fuel is constantly supplied to the injectors by the fuel rail. The
Engine Control Module (ECM) controls the fueling and timing of the engine by actuating the injectors.
Fuel enters the system from the electric fuel transfer (lift) pump, which is located inside of the fuel tank and attached
to the fuel tank module (the fuel transfer pump is no longer attached to the engine). Fuel is forced through the fuel
filter element and then enters the Fuel Pump/Gear Pump, which is attached to the rear of the fuel injection pump.
The Fuel Pump/Gear Pump is a low-pressure pump and produce pressures ranging from 551.5 kpa (80 psi) to 1241
kpa (180) psi. Fuel then enters the fuel injection pump. Low pressure fuel is then supplied to the FCA (Fuel Control
Actuator).
The FCA is an electronically controlled solenoid valve. The ECM controls the amount of fuel that enters the high-
pressure pumping chambers by opening and closing the FCA based on a demanded fuel pressure. The FPS (Fuel
Pressure Sensor) on the fuel rail monitors the actual fuel pressure and provides it as an input to the ECM. When
the actuator is opened, the maximum amount of fuel is being supplied to the fuel injection pump. Any fuel that does
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FUEL DELIVERY - DIESEL
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