Dodge Dakota (R1). Manual — part 574
Voltage to operate the fuel heater is supplied from
the ignition (key) switch and through the fuel heater
relay. (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY/FUEL HEATER RELAY - DIAGNOSIS AND
TESTING). The fuel heater and fuel heater relay
are not controlled by the Powertrain Control
Module (ECM).
If the fuel heater element needs replacement, the
plastic filter bowl assembly must be replaced. (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL
FILTER / WATER SEPARATOR - REMOVAL).
FUEL HEATER RELAY
DESCRIPTION
Voltage to operate the fuel heater is supplied from
the ignition (key) switch through the fuel heater
relay. The PCM or ECM is not used to control
this relay.
The fuel heater relay is located in the PDC. The
PDC is located next to the battery in the engine com-
partment. For the location of the relay within the
PDC, refer to label on PDC cover.
DIAGNOSIS AND TESTING - FUEL HEATER
RELAY
The fuel heater relay is located in the Power Dis-
tribution Center (PDC). Refer to Relays—Operation/
Testing in Fuel Injection System section of this group
for test procedures.
FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge sending unit is attached to the side
of the fuel pump module. The sending unit consists of
a float, an arm, and a variable resistor (track). The
track is used to send an electrical signal used for fuel
gauge operation.
As the fuel level increases, the float and arm move
up. This decreases the sending unit resistance, caus-
ing the PCM to send a signal to the fuel gauge on the
instrument panel to read full. As the fuel level
decreases, the float and arm move down. This
increases the sending unit resistance, causing the
PCM to send a signal to the fuel gauge on the instru-
ment panel to move toward empty.
REMOVAL
The fuel level sensor is located on the side of the
fuel pump module (Fig. 18).
(1) Remove fuel tank. Refer to Fuel Tank Removal/
Installation.
(2) Remove fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(3) Remove electrical wire connector at sending
unit terminals.
(4) Press on release tab (Fig. 19) to remove send-
ing unit from pump module.
Fig. 17 Fuel Heater Temperature Sensor and
Element Location
1 - TERMINAL 2
2 - FUEL HEATER
3 - TERMINAL 1
Fig. 18 Fuel Level Sensor
1 - FUEL GAUGE FLOAT
2 - FUEL GAUGE SENDING UNIT
3 - PIGTAIL WIRING HARNESS
14a - 10
FUEL DELIVERY
R1
FUEL HEATER (Continued)
INSTALLATION
(1) Install the sensor into the fuel reservoir mod-
ule.
(2) Connect the wire harness connctor to the sen-
sor.
(3) Install the fuel reservoir module into the fuel
tank.
(4) Install the fuel tank into the vehicle.
FUEL INJECTION PUMP
DESCRIPTION-TIMING SOLENOID
The timing solenoid is located on the bottom of the
fuel injection pump (Fig. 20).
This 12(+) volt, pulse width modulated (duty–cycle)
output controls the amount of fuel timing (advance)
in the fuel injection pump. The higher the duty–cy-
cle, the lower the advance. The lower the duty–cycle,
the more advanced the fuel timing.
The duty–cycle is determined by the ECM from
inputs it receives from the fuel injector sensor and
engine speed sensor.
DIAGNOSIS AND TESTING - FUEL INJECTION
PUMP
The injection pump is not to be serviced or
the warranty may be voided. If the injection
pump requires service, the complete assembly
must be replaced.
Incorrect injection pump timing (mechanical or
electrical) can cause poor performance, excessive
smoke and emissions and poor fuel economy.
A defective fuel injection pump, defective fuel tim-
ing solenoid or misadjusted mechanical pump timing
can cause starting problems or prevent the engine
from revving up. It can also cause:
• Engine surge at idle
• Rough idle (warm engine)
• Low power
• Excessive fuel consumption
• Poor performance
• Low power
• Black smoke from the exhaust
• Blue or white fog like exhaust
• Incorrect idle or maximum speed
The electronically controlled fuel pump has no
mechanical governor like older mechanically con-
trolled fuel pumps. Do not remove the top cover of
the fuel pump, or the screws fastening the wiring
pigtail to the side of the pump. The warranty of
the injection pump and the engine may be void
if those seals have been removed or tampered
with.
Fig. 20 Timing Solenoid
1 - FUEL INJECTION PUMP ASSEMBLY
2 - FUEL RETURN LINE
3 - FUEL SUPPLY LINE
4 - FUEL INJECTION PUMP 10–WAY CONNECTOR
5 - TIMING SOLENOID
6 - OVERFLOW VALVE
Fig. 19 Fuel Level Sensor Release Tab
1 - ELECTRICAL CONNECTOR
2 - FUEL LEVEL SENSOR
3 - RELEASE TAB
4 - FUEL RESERVOIR MODULE
R1
FUEL DELIVERY
14a - 11
FUEL LEVEL SENDING UNIT / SENSOR (Continued)
STANDARD PROCEDURES - AIR BLEED
PROCEDURES
AIR BLEEDING AT FUEL FILTER
A certain amount of air may become trapped in the
fuel system when fuel system components are ser-
viced or replaced. Bleed the system as needed after
fuel system service according to the following proce-
dures.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
Some air enters the fuel system when the fuel fil-
ter or injection pump supply line is changed. This
small amount of air is vented automatically from the
injection pump through the fuel drain manifold tubes
if the filter was changed according to instructions.
Ensure the the fuel filter/water separator is full of
fuel
It may be necessary to manually bleed the system
if:
• The bowl of the fuel filter/water separator is not
partially filled before installation of a new filter
• The injection pump is replaced
• High–pressure fuel line connections are loosened
or lines replaced
• Initial engine start–up or start–up after an
extended period of no engine operation
• Running fuel tank empty
FUEL INJECTION PUMP BLEEDING
(1) If the fuel injection pump has been replaced,
air should be bled at the overflow valve before
attempting to start engine.
(a) Loosen the overflow valve (Fig. 21) at the
rear of the injection pump.
(b) Place a towel below the valve.
WARNING: WHEN CRANKING THE ENGINE TO
BLEED AIR FROM THE INJECTION PUMP, THE
ENGINE MAY START. PLACE THE TRANSMISSION
IN NEUTRAL OR PARK AND SET PARKING BRAKE
BEFORE ENGAGING THE STARTER MOTOR.
CAUTION: Do not engage the starter motor for more
than 30 seconds at a time. Allow 2 minutes between
cranking intervals.
(2) Crank the engine for 30 seconds at a time to
allow air trapped in the injection pump to vent out
the fuel injector drain tubes. Continue this procedure
until the engine starts. Observe the previous WARN-
ING and CAUTION.
(3) Tighten overflow valve.
HIGH–PRESSURE FUEL LINE BLEEDING
WARNING: THE INJECTION PUMP SUPPLIES HIGH–
PRESSURE FUEL OF APPROXIMATELY 45,000 KPA
(6,526
PSI)
TO
EACH
INDIVIDUAL
INJECTOR
THROUGH
THE
HIGH–PRESSURE
LINES.
FUEL
UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE THE SKIN AND CAUSE PERSONAL INJURY.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING AND AVOID CONTACT WITH
FUEL SPRAY WHEN BLEEDING HIGH–PRESSURE
FUEL LINES.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
Bleed air from one injector at time.
(1) Loosen the high–pressure fuel line fitting at
the injector (Fig. 22).
(2) Crank the engine until all air has been bled
from the line. Do not operate the starter motor
for longer than 30 seconds. Wait 2 minutes
between cranking intervals.
(3) Start the engine and bleed one injector at a
time until the engine runs smoothly.
Fig. 21 Overflow Valve
1 - FUEL INJECTION PUMP ASSEMBLY
2 - FUEL RETURN LINE
3 - FUEL SUPPLY LINE
4 - FUEL INJECTION PUMP 10–WAY CONNECTOR
5 - TIMING SOLENOID
6 - OVERFLOW VALVE
14a - 12
FUEL DELIVERY
R1
FUEL INJECTION PUMP (Continued)
STANDARD PROCEDURE - INJECTION PUMP
TIMING
Refer to the Fuel Injection Pump Removal and
Installation procedure in Service Procedures later in
this Group.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Thoroughly clean the area around the injection
pump and fuel lines of all dirt, grease and other con-
taminants. Due to the close internal tolerances
of the injection pump, this step must be per-
formed before removing pump.
(3) Remove the engine accessory drive belt. Refer
to Group 7, Cooling System for procedures.
(4) Remove the generator assembly.
(5) Remove the rubber fuel return and supply
hoses from the metal lines at the pump (Fig. 23).
(6) Remove the electrical connector at engine cool-
ant temperature sensor.
(7) Disconnect the Fuel Injection Pump electrical
connector at fuel pump. (Fig. 23).
(8) Disconnect the main engine wiring harness
from the glow plugs.
(9) Disconnect the four high–pressure fuel lines
from the fuel injection pump. Also disconnect fuel
lines at the fuel injectors. For procedures, refer to
High–Pressure Fuel Lines in this group. Place a rag
beneath the fittings to catch excess fuel.
(10) Remove the plug from timing gear cover.
(11) The “Top Dead Center” (TDC) compression fir-
ing stroke for the #1 cylinder can be determined as
follows:
(a) Using a socket attached to the front of the
crankshaft, rotate the engine clockwise until spe-
cial alignment tool VM.1043 can be inserted
through the hole in the bottom of the clutch hous-
ing, stopping the flywheel rotation. This position is
TDC or 180° away from TDC. Engine must be at
TDC #1 compression firing stroke.
(b) To verify that you are at #1 TDC Compres-
sion. Remove the oil fill cap from the cylinder head
cover and the alignment tool from the clutch hous-
ing.
(c) Rotate the crankshaft one-quarter turn clock-
wise and counter-clockwise while observing the
rocker arm through the oil fill cap hole. If the
rocker arm moves you are not at #1 TDC Compres-
sion.
(d) If #1 TDC Compression was found continue,
if not rotate the crankshaft one revolution until the
alignment tool can be re-installed in the flywheel.
You are now at TDC for the #1 cylinder compres-
sion firing stroke. Mark the damper and timing
cover for reference to TDC. Remove the alignment
tool from the clutch housing.
Fig. 22 Bleeding High–Pressure Fuel Line—Typical
1 - FUEL INJECTOR
2 - LINE FITTING
3 - HIGH-PRESSURE FUEL LINE
4 - FUEL DRAIN TUBES
Fig. 23 Fuel Injection Pump
1 - FUEL INJECTION PUMP ASSEMBLY
2 - FUEL RETURN LINE
3 - FUEL SUPPLY LINE
4 - FUEL INJECTION PUMP 10–WAY CONNECTOR
5 - FUEL TIMING SOLENOID
R1
FUEL DELIVERY
14a - 13
FUEL INJECTION PUMP (Continued)
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