Dodge Dakota (R1). Manual — part 573
(18) Inspect the air cleaner element (filter) for
restrictions.
(19) Be sure that the turbocharger output hose is
properly connected to the charge air cooler (inter-
cooler) inlet tube. Verify that the charge air cooler
output hose is properly connected to the cooler and
the intake manifold. Refer to Group 11, Exhaust Sys-
tem and Intake Manifold for information.
(20) Be sure that the vacuum hoses to the vacuum
pump are connected and not leaking. The vacuum
pump is located in the front of engine (internal) and
is driven from the crankshaft gear (Fig. 11). Discon-
nect the hose and check for minimum vacuum from
the pump. Refer to Group 5, Brake System for spec-
ifications and procedures.
(21) Be sure that the accessory drive belt is not
damaged or slipping.
(22) Verify there is a good connection at the engine
speed sensor. Refer to the Fuel Injection System in
this section for location of the engine speed sensor
location.
(23) Verify there is a good connection at the Boost
Pressure Sensor.
SPECIFICATIONS
FUEL INJECTOR FIRING SEQUENCE
1–3–4–2
Fig. 10 Engine Coolant Temperature Sensor
Location
1 - PCM ENGINE COOLANT TEMPERATURE (ECT) SENSOR
2 - ECM ENGINE COOLANT TEMPERATURE (ECT) SENSOR
3 - ECM ECT SENSOR HARNESS CONNECTOR
4 - PCM ECT SENSOR HARNESS CONNECTOR
Fig. 11 Vaccum Pump at Front of Engine
1 - VACUUM PUMP
2 - CAMSHAFT
3 - INJECTION PUMP
4 - TIMING MARKS
5 - OIL PUMP
6 - CRANKSHAFT
14a - 6
FUEL DELIVERY
R1
FUEL DELIVERY (Continued)
FUEL TANK
DESCRIPTION
The fuel tank and tank mounting used with the
diesel powered engine is the same as used with gas-
oline powered models, although the fuel tank module
is different.
The fuel tank contains the fuel tank module and
one rollover valve. Two fuel lines are routed to the
fuel tank module. One line is used for fuel supply to
the fuel filter/water separator. The other is used to
return excess fuel back to the fuel tank.
The fuel tank module contains the fuel gauge elec-
trical sending unit. An electric fuel pump is not
used with the diesel engine.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Insert fuel siphon hose into fuel filler neck and
push it into the tank.
(3) Drain fuel tank dry into holding tank or a
properly labeled diesel safety container.
(4) Raise vehicle on hoist.
(5) Disconnect both the fuel fill and fuel vent rub-
ber hoses at the fuel tank (Fig. 13).
(6) Disconnect fuel supply and return lines from
the steel supply line (Fig. 12).
The fuel reservoir module electrical connec-
tor has a retainer that locks it in place.
(7) Slide electrical connector lock to unlock.
(8) Push down on connector retainer (Fig. 14) and
pull connector off module.
(9) Use a transmission jack to support fuel tank.
Remove bolts from fuel tank straps.
(10) Lower tank slightly. Carefully remove filler
hose from tank.
Fig. 12 Fuel Tank Connections at Front of Tank
1 - FUEL SUPPLY LINE CONNECTION
2 - FUEL PUMP MODULE CONNECTOR
3 - FRONT OF FUEL TANK
4 - EVAP CANISTER VENT LINE CONNECTION
Fig. 13 Fuel Fill/Vent Hose Index Marks
1 - FUEL TANK
2 - CLAMP INDEX MARKS
3 - TANK INDEX TANGS
4 - HOSE INDEX MARKS
5 - FUEL FILL HOSE
6 - CLAMP INDEX MARKS
7 - CLAMPS
8 - FUEL VENT HOSE
Fig. 14 Module Connector Retainer and Lock
1 - PUSH DOWN ON RETAINER
2 - CONNECTOR LOCK
R1
FUEL DELIVERY
14a - 7
(11) Lower the fuel tank. Remove clamp and
remove fuel filler tube vent hose. Remove fuel tank
from vehicle.
INSTALLATION
(1) Position fuel tank on transmission jack. Con-
nect fuel filler tube vent hose and replace clamp.
(2) Raise tank into position and carefully work
filler tube into tank. A light coating of clean engine
oil on the tube end may be used to aid assembly.
(3) Feed filler vent line thorough frame rail. Care-
ful not to cross lines.
(4) Tighten strap bolts to 9 N·m (80 in. lbs.).
Remove transmission jack.
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(5) Connect
module
electrical
connector.
Place
retainer in locked position.
(6) Lubricate the fuel supply and return lines with
clean 30 weight engine oil, install the quick connect
fuel fitting. Refer to Tube/Fitting Assembly in the
Fuel Delivery section of this Group.
(7) Attach filler line to filler tube. Pull on connec-
tor to make sure of connection.
(8) Fill fuel tank, replace cap, and connect battery
negative cable.
FUEL DRAIN TUBES
DESCRIPTION
These rubber tubes are low–pressure type. Some
fuel is continually being returned to the fuel injection
pump. During injection, a small amount of fuel flows
past the injector needle and is not injected into the
combustion chamber. This cools and lubricates the
injectors. This fuel flows through the fuel drain tubes
(Fig. 15) and back to the tee banjo fitting, which is
connected to the same line as the overflow valve. The
overflow valve is calibrated to open at a preset pres-
sure. Excess fuel not required by the pump to main-
tain the minimum pump cavity pressure is then
returned through the overflow valve and on to the
fuel tank through the fuel return line.
FUEL FILTER / WATER
SEPARATOR
DESCRIPTION
The fuel filter/water separator is located in the
engine compartment on the left side near the shock
tower (Fig. 16).
The fuel filter/water separator assembly contains
the fuel filter, fuel heater element, and fuel drain
valve (Fig. 16).
STANDARD PROCEDURE - FUEL FILTER/
WATER SEPARATOR
Moisture (water) collects at the bottom of the filter/
separator in a plastic bowl. Water entering the fuel
injection pump can cause serious damage to the
pump. Note that the bulb will be illuminated for
approximately 2 seconds each time the key is
initially placed in the ON position. This is done
for a bulb check.
WARNING: DO NOT ATTEMPT TO DRAIN WATER
FROM THE FILTER/SEPARATOR WITH THE ENGINE
HOT.
(1) The bottom of the filter/separator bowl is
equipped with a drain valve (Fig. 16). The drain
valve is equipped with a fitting. Attach a piece of
rubber hose to this fitting. This hose is to be used as
a drain hose.
(2) Place a drain pan under the drain hose.
(3) With the engine not running, open the drain
valve (unscrew—drain valve has right hand threads)
from the filter/separator bowl. To gain access to this
fitting, the two filter–to–mounting bracket nuts (Fig.
16) may have to be loosened a few turns.
(4) Hold the drain open until clean fuel exits the
drain.
(5) After draining, close drain valve.
(6) Remove rubber drain hose.
(7) Dispose of mixture in drain pan according to
applicable local or federal regulations.
REMOVAL
(1) Drain all fuel and/or water from fuel filter/wa-
ter separator assembly. Refer to the previous Drain-
ing Water From Filter Bowl.
(2) Unplug the electrical connectors at bottom of
plastic bowl.
(3) Remove plastic bowl from bottom of fuel filter
(unscrews).
Fig. 15 Fuel Drain Tubes
14a - 8
FUEL DELIVERY
R1
FUEL TANK (Continued)
(4) Remove fuel filter from bottom of filter base
(unscrews).
INSTALLATION
(1) Clean bottom of fuel filter base.
(2) Apply clean diesel fuel to new fuel filter gasket.
(3) Install and tighten filter to filter base. The bev-
eled part of the rubber gasket should be facing up
towards the filter base.
(4) Clean the inside of bowl with a soap and water
mixture before installation. Carefully clean any resi-
due between the two metal probes at the top of the
water–in–fuel sensor. Do not use chemical cleaners
as damage to the plastic bowl may result.
(5) Pour diesel fuel into the plastic bowl before
installing bowl to bottom of fuel filter. Do this to help
prevent air from entering fuel injection pump while
attempting to starting engine.
(6) Install filter bowl to bottom of filter.
(7) Install the electrical connectors at bottom of
bowl.
(8) Tighten the filter–to–mounting bracket nuts to
28 N·m (250 in. lbs.) torque.
FUEL HEATER
DESCRIPTION
The fuel heater is used to prevent diesel fuel from
waxing and plugging the fuel filter during cold
weather operation. The fuel heater is located in the
bottom plastic bowl of the fuel filter/water separator
(Fig. 17).
The element inside the heater assembly is made of
a Positive Temperature Coefficient (PTC) material,
and has power applied to it by the fuel heater relay
anytime the ignition key is in the “on” position. PTC
material has a high resistance to current flow when
its temperature is high, which means that it will not
generate heat when the temperature is above a cer-
tain value. When the temperature is below 7°C (45°
F), the resistance of the PTC element is lowered, and
allows current to flow through the fuel heater ele-
ment warming the fuel. When the temperature is
above 29°C (85° F), the PTC element’s resistance
rises, and current flow through the heater element
stops.
Fig. 16 Fuel
1 - COOLANT RESERVE/OVERFLOW TANK
2 - FUEL HEATER/WATER SEPARATOR
3 - HYDRAULIC CLUTCH FLUID RESERVOIR
4 - LOW COOLANT LEVEL SWITCH
R1
FUEL DELIVERY
14a - 9
FUEL FILTER / WATER SEPARATOR (Continued)
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