Dodge Dakota (R1). Manual — part 575
(12) Remove access plug and plug washer at rear
of pump (Fig. 24). Thread special dial indicator and
adapter tool VM.1011 (Fig. 25)into this opening.
Hand tighten only.
(13) Slightly rotate the engine in a counter-clock-
wise direction until the dial gauge indicator stops
moving (20°-25° before TDC).
(14) Remove injection pump drive gear nut (Fig.
26).
(15) A special
3–piece
gear
removal
tool
set
VM.1003 (Fig. 27) must be used to remove the injec-
tion pump drive gear from the pump shaft.
(a) Thread the adapter (Fig. 28) into the timing
cover.
(b) Thread the gear puller into the injection
pump drive gear (Fig. 28). This tool is also used to
hold the gear in synchronization during pump
removal.
Fig. 24 Access Plug at Rear of Pump
1 - ACCESS PLUG
2 - WASHER
Fig. 25 Installing Dial Indicator and Special Adapter
Tools
1 - DIAL INDICATOR TOOL
2 - ADAPTER TOOL VM.1011
Fig. 26 Removing Pump Drive Gear Nut
1 - TIMING GEAR COVER
2 - INJECTION PUMP GEAR
3 - PUMP GEAR NUT
Fig. 27 Pump Gear Tools
1 - DRIVE BOLT
2 - TIMING COVER ADAPTER
3 - GEAR PULLER
14a - 14
FUEL DELIVERY
R1
FUEL INJECTION PUMP (Continued)
(c) Remove the three injection pump–to–gear
cover mounting nuts (Fig. 29). CAUTION: This
step must be done to prevent injection pump
damage.
(d) Install the drive bolt into the gear puller
(Fig. 28). Tighten the drive bolt to press (remove)
the drive gear from injection pump shaft while
driving injection pump rearward from timing gear
cover mounting studs.
(16) Remove pump from engine. Do not rotate
engine while gear puller is installed. Engine
damage will occur.
INSTALLATION/ADJUSTING PUMP TIMING
(1) Clean the mating surfaces of injection pump
and timing gear cover.
(2) Install a new injection pump–to–timing gear
cover gasket.
(3) Remove the gear removing bolt (drive bolt)
from gear puller. CAUTION: Do not remove the
special gear puller or timing cover adapter
tools from timing cover at this time. Gear mis-
alignment will result.
(4) Place the key way on the pump shaft to the 11
o’clock position as viewed from the front of pump.
Install the pump into the rear of timing gear cover
while aligning key way on pump shaft into pump
gear.
(5) Install and snug the 3 injection pump mount-
ing nuts. This is not the final tightening sequence.
(6) Remove the special gear puller and adapter
tools from timing gear cover.
(7) Install the injection pump drive gear nut.
Tighten nut to 88 N·m (65 ft. lbs.) torque.
(8) Remove the access plug and plug washer at
rear of pump (Fig. 30). Thread special dial indicator
adapter tool VM.1011 (Fig. 31) into this opening.
Hand tighten only.
Fig. 28 Installing Pump Drive Gear Removal Tools
1 - ADAPTER
2 - DRIVE BOLT
3 - GEAR PULLER
Fig. 29 Injection Pump Mounting Nuts
1 - MOUNTING FLANGE
2 - SLOTTED HOLES (3)
3 - PUMP MOUNTING NUTS (3)
Fig. 30 ACCESS PLUG AT REAR OF PUMP
1 - ACCESS PLUG
2 - WASHER
R1
FUEL DELIVERY
14a - 15
FUEL INJECTION PUMP (Continued)
(9) Attach special dial indicator tool VM.1013 into
the adapter tool (Fig. 31)
(10) Using a socket attached to the front of the
crankshaft, rotate the engine in a counter-clockwise
direction until the dial gage indicator stops moving
(20–25° before TDC).
(11) Set the dial indicator to 0mm. Be sure the tip
of the dial indicator is touching the tip inside the
adapter tool.
(12) Rotate the engine clockwise until special
alignment tool VM.1043 can be inserted through the
hole in the bottom of the clutch housing, stopping the
flywheel rotation. This position is #1 Cylinder TDC
Compression. Engine must be at TDC #1 com-
pression firing stroke.
(13) The gauge reading should be at 0.55 mm
(with new gears installed specification should
be 0.59–0.60mm). If not, the pump must be rotated
for adjustment:
(a) Loosen the three injection pump mounting
nuts at the mounting flanges. These flanges are
equipped with slotted holes. The slotted holes are
used to rotate and position the injection pump for
fuel timing. Loosen the three nuts just enough to
rotate the pump.
(b) Rotate the pump until 0.55 mm is indicated
on the dial indicator gauge. If while rotating the
pump the 0.55 mm specification is passed do not
attempt to rotate the pump in the opposite direc-
tion. You must rotate the pump back below the
0.25 mm specification and start the procedure over
from the start of the TDC procedure. This will pre-
vent a false reading due to gear backlash.
(c) Tighten the three pump mounting nuts to 30
N·m (22 ft. lbs.) torque.
(d) Recheck the dial indicator after tightening
the pump mounting nuts. Gauge should still be
reading 0.55 mm.
(14) Remove dial indicator and adapter tools.
(15) Install access plug and washer to rear of
injection pump.
(16) Install plug at timing gear cover.
(17) Install and connect the four high–pressure
fuel lines to the fuel injection pump. Also connect
fuel lines at the fuel injectors. For procedures, refer
to High–Pressure Fuel Lines in this group.
(18) Install electrical connector at engine coolant
temperature sensor.
(19) Connect electrical connector at fuel shutdown
solenoid.
(20) Connect the main engine wiring harness to
the glow plugs.
(21) Connect the fuel timing solenoid pigtail har-
ness to the engine wiring harness.
(22) Connect the overflow valve/banjo fitting (fuel
return line assembly). Replace copper gaskets before
installing.
(23) Connect the rubber fuel return and supply
hoses to metal lines at pump. Tighten hose clamps to
2 N·m (20 in. lbs.) torque.
(24) Install generator assembly.
(25) Install engine accessory drive belt. Refer to
Group 7, Cooling System for procedures.
(26) Install negative battery cable to battery.
(27) Start the engine and bring to normal operat-
ing temperature.
(28) Check for fuel leaks.
FUEL TANK MODULE
DESCRIPTION
An electric fuel pump is not attached to the fuel
tank module for diesel powered engines. Fuel is
drawn by the fuel injection pump.
The fuel tank module is installed in the top of the
fuel tank. The fuel tank module contains the follow-
ing components:
• Fuel reservoir
• Electric fuel gauge sending unit
• Fuel supply line connection
• Fuel return line connection
• Wire harness
• Fuel inlet filter (Strainer)
Fig. 31 INSTALLING DIAL INDICATOR AND SPECIAL
ADAPTER TOOLS
1 - DIAL INDICATOR
2 - ADAPTER TOOL VM.1011
14a - 16
FUEL DELIVERY
R1
FUEL INJECTION PUMP (Continued)
FUEL RESERVOIR MODULE
REMOVAL
WARNING: THE FUEL RESERVOIR OF THE FUEL
MODULE DOES NOT EMPTY OUT WHEN THE TANK
IS DRAINED. THE FUEL IN THE RESERVOIR WILL
SPILL OUT WHEN THE MODULE IS REMOVED.
(1) Disconnect negative cable from battery.
(2) Drain fuel tank dry into holding tank or a
properly labeled diesel safety container.
(3) Raise vehicle on hoist.
(4) Use a transmission jack to support the fuel
tank. Remove bolts from fuel tank straps. Lower
tank slightly.
(5) Clean area around fuel reservoir module and
tank to keep dirt and foreign material out of tank.
(6) Disconnect fuel lines from fuel module by
depressing quick connect retainers with thumb and
fore finger.
(7) Slide
module
electrical
connector
lock
to
unlock.
(8) Push down on connector retainer and pull con-
nector off module.
(9) Using Special Tool 6856, remove plastic locknut
counterclockwise to release pump module (Fig. 32).
(10) Carefully remove module and o-ring from
tank.
(11) Discard old o-ring.
INSTALLATION
(1) Thoroughly clean locknut threads and mating
fule tank threads. Use a soap/water solution. Do Not
use carburetor cleaner to clean threads.
(2) Apply clean water to the o-ring seal and place
on the mating fuel tank threads.
(3) Wipe seal area of tank clean and place a new
o-ring seal in position on pump.
(4) Position fuel reservoir module in tank with
locknut.
(5) Tighten locknut to 75 N·m (55 ft. lbs.).
(6) Connect fuel lines.
(7) Plug in electrical connector. Slide connector
lock into position.
(8) Raise fuel tank, install bolts into fuel tank
straps and tighten.
(9) Lower vehicle on hoist.
(10) Connect negative cable from battery.
(11) Fill fuel tank. Check for leaks.
(12) Install fuel filler cap.
FUEL HIGH PRESSURE LINES
DESCRIPTION
Different types of quick-connect fittings are used to
attach various fuel system components. These are: a
single-tab type, a two-tab type or a plastic retainer
ring type. Refer to Quick-Connect Fittings in the
Removal/Installation section for more information.
CAUTION: The interior components (o-rings, spac-
ers) of quick-connect fitting are not serviced sepa-
rately, but new pull tabs are available for some
types. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
DESCRIPTION
Also refer to the proceeding section on Quick–Con-
nect Fittings.
Inspect all hose connections such as clamps, cou-
plings and fittings to make sure they are secure and
leaks are not present. The component should be
replaced immediately if there is any evidence of deg-
radation that could result in failure.
Never attempt to repair a plastic fuel line/tube or a
quick–connect fitting. Replace complete line/tube as
necessary.
Avoid contact of any fuel tubes/hoses with other
vehicle components that could cause abrasions or
scuffing. Be sure that the fuel lines/tubes are properly
routed to prevent pinching and to avoid heat sources.
The lines/tubes/hoses are of a special construction.
If it is necessary to replace these lines/tubes/hoses,
use only original equipment type.
The hose clamps used to secure the rubber hoses
are of a special rolled edge construction. This con-
struction is used to prevent the edge of the clamp
from cutting into the hose. Only these rolled edge
type clamps may be used in this system. All other
Fig. 32 Fuel Reservoir Module Lock Nut Removal
1 - SPECIAL TOOL 6856
2 - LOCKNUT
R1
FUEL DELIVERY
14a - 17
FUEL TANK MODULE (Continued)
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