Dodge Durango (DN). Manual — part 10
flow back into the tank and to maintain fuel supply
line pressure (engine warm) when pump is not oper-
ational. 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 between the check valve
and
fuel
injectors.
Fuel
pressure
that
has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the elec-
tric fuel pump is activated, fuel pressure should
immediately (1–2 seconds) rise to specification.
Abnormally long periods of cranking to restart a
hot engine that has been shut down for a short
period of time may be caused by:
• Fuel pressure bleeding past a fuel injector(s).
• Fuel pressure bleeding past the check valve in
the fuel pump module.
(1) Disconnect the fuel inlet line at fuel rail. Refer
to Fuel Tubes/Lines/Hoses and Clamps in this section
of the group for procedures. On some engines, air
cleaner housing removal may be necessary before
fuel line disconnection.
(2) Obtain correct Fuel Line Pressure Test Adapter
Tool Hose. Tool number 6539 is used for 5/16” fuel
lines and tool number 6631 is used for 3/8” fuel lines.
(3) Connect
correct
Fuel
Line
Pressure
Test
Adapter Tool Hose between disconnected fuel line
and fuel rail (Fig. 8).
(4) Connect the 0-414 kPa (0-60 psi) fuel pressure
test gauge (from Gauge Set 5069) to the test port on
the appropriate Adaptor Tool. The DRB III Scan
Tool along with the PEP module, the 500 psi
pressure transducer, and the transducer-to-test
port adapter may also be used in place of the
fuel pressure gauge.
The fittings on both tools must be in good
condition and free from any small leaks before
performing the proceeding test.
(5) Start engine and bring to normal operating
temperature.
(6) Observe test gauge. Normal operating pressure
should be 339 kPa
6 34 kPa (49.2 psi 6 5 psi).
(7) Shut engine off.
(8) Pressure should not fall below 30 psi for five
minutes.
(9) If pressure falls below 30 psi, it must be deter-
mined if a fuel injector, the check valve within the
fuel pump module, or a fuel tube/line is leaking.
(10) Again, start engine and bring to normal oper-
ating temperature.
(11) Shut engine off.
(12) Testing for fuel injector or fuel rail leak-
age: Clamp off the rubber hose portion of Adaptor
Tool between the fuel rail and the test port “T” on
Adapter Tool. If pressure now holds at or above 30
psi, a fuel injector or the fuel rail is leaking.
(13) Testing for fuel pump check valve, filter/
regulator check valve or fuel tube/line leakage:
Clamp off the rubber hose portion of Adaptor Tool
between the vehicle fuel line and test port “T” on
Adapter Tool. If pressure now holds at or above 30
psi, a leak may be found at a fuel tube/line. If no
leaks are found at fuel tubes or lines, one of the
check valves in either the electric fuel pump or filter/
regulator may be leaking.
Note: A quick loss of pressure usually indicates a
defective check valve in the filter/regulator. A slow
loss of pressure usually indicates a defective check
valve in the electric fuel pump.
The electric fuel pump is not serviced separately.
Replace the fuel pump module assembly. The filter/
regulator may be replaced separately on certain
applications. Refer to Fuel Filter/Fuel Pressure Reg-
ulator Removal/Installation for additional informa-
tion.
FUEL PUMP AMPERAGE TEST
This amperage (current draw) test is to be done in
conjunction with the Fuel Pump Pressure Test, Fuel
Pump Capacity Test and Fuel Pressure Leak Down
Test. Before performing the amperage test, be sure
Fig. 8 Connecting Adapter Tool—Typical
1 – VEHICLE FUEL LINE
2 – TEST PORT “T”
3 – SPECIAL TOOL 6923, 6631, 6541 OR 6539
4 – FUEL PRESSURE TEST GAUGE
5 – FUEL LINE CONNECTION AT RAIL
6 – FUEL RAIL
14 - 8
FUEL SYSTEM
DN
DIAGNOSIS AND TESTING (Continued)
the temperature of the fuel tank is above 50° F (10°
C).
The DRB Scan Tool along with the DRB Low Cur-
rent Shunt (LCS) adapter (Fig. 9) and its test leads
will be used to check fuel pump amperage specifica-
tions.
(1) Obtain LCS adapter.
(2) Plug cable from LCS adapter into DRB scan
tool at SET 1 receptacle.
(3) Plug DRB into vehicle 16–way connector (data
link connector).
(4) Connect (-) and (+) test cable leads into LCS
adapter receptacles. Use 10 amp (10A +) receptacle
and common (-) receptacles.
(5) Gain access to MAIN MENU on DRB screen.
(6) Press DVOM button on DRB.
(7) Using left/right arrow keys, highlight CHAN-
NEL 1 function on DRB screen.
(8) Press ENTER three times.
(9) Using up/down arrow keys, highlight RANGE
on DRB screen (screen will default to 2 amp scale).
(10) Press ENTER to change 2 amp scale to 10
amp scale. This step must be done to prevent
damage to DRB scan tool or LCS adapter
(blown fuse).
(11) Remove cover from Power Distribution Center
(PDC).
(12) Remove fuel pump relay from PDC. Refer to
label on PDC cover for relay location.
WARNING: BEFORE PROCEEDING TO NEXT STEP,
NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI-
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND FUEL
SYSTEM COMPONENTS ARE CONNECTED.
CAUTION: TO PREVENT POSSIBLE DAMAGE TO
THE VEHICLE ELECTRICAL SYSTEM AND LCS
ADAPTER, THE TEST LEADS MUST BE CON-
NECTED
INTO
RELAY
CAVITIES
EXACTLY
AS
SHOWN IN FOLLOWING STEPS.
Depending upon vehicle model, year or engine con-
figuration, three different types of relays may be
used: Type-1, type-2 and type–3.
(13) If equipped with type–1 relay (Fig. 10),
attach test leads from LCS adapter into PDC relay
cavities number 30 and 87. For location of these cav-
ities, refer to numbers stamped to bottom of relay
(Fig. 10).
(14) If equipped with type–2 relay (Fig. 11),
attach test leads from LCS adapter into PDC relay
cavities number 30 and 87. For location of these cav-
ities, refer to numbers stamped to bottom of relay
(Fig. 11).
(15) If equipped with type–3 relay (Fig. 12),
attach test leads from LCS adapter into PDC relay
cavities number 3 and 5. For location of these cavi-
ties, refer to numbers stamped to bottom of relay
(Fig. 12).
(16) When LCS adapter test leads are attached
into relay cavities, fuel pump will be activated.
Determine fuel pump amperage on DRB screen.
Amperage should be below 10.0 amps. If amperage is
below 10.0 amps, and specifications for the Fuel
Pump Pressure, Fuel Pump Capacity and Fuel Pres-
sure Leak Down tests were met, the fuel pump mod-
ule is OK.
(17) If amperage is more than 10.0 amps, replace
fuel pump module assembly. The electric fuel pump
is not serviced separately.
(18) Disconnect test leads from relay cavities
immediately after testing.
FUEL GAUGE SENDING UNIT
The fuel gauge sending unit contains a variable
resistor (track). As the float moves up or down, elec-
trical resistance will change. Refer to Group 8E,
Instrument Panel and Gauges for Fuel Gauge test-
ing. To test the gauge sending unit only, it must be
removed from vehicle. The unit is part of the fuel
pump module. Refer to Fuel Pump Module Removal/
Fig. 9 Low Current Shunt Adapter
1 – LOW CURRENT SHUNT ADAPTER
2 – PLUG TO DRB
3 – TEST LEAD RECEPTACLES
DN
FUEL SYSTEM
14 - 9
DIAGNOSIS AND TESTING (Continued)
Installation for procedures. Measure the resistance
across the sending unit terminals. With float in up
position, resistance should be 20 ohms
66 ohms.
With float in down position, resistance should be 220
ohms
66 ohms.
FUEL INJECTOR TEST
To perform a complete test of the fuel injectors and
their circuitry, use the DRB scan tool and refer to the
appropriate Powertrain Diagnostics Procedures man-
ual. To test the injector only, refer to the following:
Disconnect the fuel injector wire harness connector
from the injector. The injector is equipped with 2
electrical terminals (pins). Place an ohmmeter across
the terminals. Resistance reading should be approxi-
mately 12 ohms
61.2 ohms at 20°C (68°F).
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fill cap.
(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.
TERMINAL LEGEND
NUMBER
IDENTIFICATION
30
COMMON FEED
85
COIL GROUND
86
COIL BATTERY
87
NORMALLY OPEN
87A
NORMALLY CLOSED
Fig. 10 Type–1 Relay
TERMINAL LEGEND
NUMBER
IDENTIFICATION
30
COMMON FEED
85
COIL GROUND
86
COIL BATTERY
87
NORMALLY OPEN
87A
NORMALLY CLOSED
Fig. 11 Type–2 Relay
TERMINAL LEGEND
NUMBER
IDENTIFICATION
1
COIL BATTERY
2
COIL GROUND
3
COMMON FEED
4
NORMALLY CLOSED
5
NORMALLY OPEN
Fig. 12 Type–3 Relay
14 - 10
FUEL SYSTEM
DN
DIAGNOSIS AND TESTING (Continued)
(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.
(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 DRB scan tool must be
used to erase a DTC.
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.
DISCONNECTING
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 line. If repair is necessary, replace complete
fuel line assembly.
(1) Perform fuel pressure release procedure. Refer
to Fuel Pressure Release Procedure in this group.
(2) Disconnect negative battery cable from battery.
(3) Clean fitting of any foreign material before dis-
assembly.
(4)
Single-Tab Type Fitting: This type of fitting
is equipped with a single pull tab (Fig. 13). The tab
is removable. After tab is removed, quick-connect fit-
ting can be separated from fuel system component.
(a) Press release tab on side of fitting to release
pull tab (Fig. 14). 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. 14).
(c) Raise pull tab until it separates from quick-
connect fitting (Fig. 15).
(5) Two-Tab Type Fitting: This type of fitting is
equipped with tabs located on both sides of fitting
(Fig. 16). The tabs are supplied for disconnecting
quick-connect fitting from component being serviced.
(a) To disconnect quick-connect fitting, squeeze
plastic retainer tabs (Fig. 16) against sides of
quick-connect fitting with your fingers. Tool use is
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.
Fig. 13 Single-Tab Type Fitting
1 – PULL TAB
2 – QUICK-CONNECT FITTING
3 – PRESS HERE TO REMOVE PULL TAB
4 – INSERTED TUBE END
DN
FUEL SYSTEM
14 - 11
SERVICE PROCEDURES (Continued)
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