Dodge Dakota (R1). Manual — part 560
INSTALLATION
CAUTION: Whenever fuel pump module is serviced,
the module gasket must be replaced.
(1) Using a new gasket, position fuel pump module
into opening in fuel tank. Be sure rubber gasket
remains in place. 2 Door Models: Rotate module
assembly until module alignment arrow is at 7
o’clock position (Fig. 14). The front of fuel tank is to
the right in (Fig. 14). Arrow should be pointed to fuel
tank markings (Fig. 14). 4 Door Models: Rotate
module assembly until module alignment arrow is at
4 o’clock position (Fig. 15). The front of fuel tank is to
the right in (Fig. 15). Arrow should be pointed to fuel
tank markings (Fig. 15). This step must be followed
to prevent float/float rod from contacting sides of fuel
tank.
(2) Position locknut over top of fuel pump module.
Tighten finger tight.
(3) Carefully rotate fuel filter/fuel pressure regula-
tor until fuel fitting is pointed towards drivers side of
vehicle (Fig. 14) or (Fig. 15). The front of fuel tank is
to the right in (Fig. 14) or (Fig. 15).
(4) Install Special Tool 6856 to locknut.
(5) Tighten locknut to 54 N·m (40 ft. lbs.) torque.
While tightening locknut, be sure module has not
rotated.
(6) Install fuel tank. Refer to Fuel Tank Installa-
tion.
Fig. 14 Top View of Fuel Pump Module—2 Door
Models
1 - LOCKNUT
2 - TANK FITTINGS
3 - EVAP FITTING
4 - ROLLOVER VALVE
5 - MODULE ALIGNMENT ARROW (7 O’CLOCK)
6 - TANK MARKINGS
7 - FUEL TANK
Fig. 15 Top View of Fuel Pump Module—4 Door
Models
1 - MODULE ALIGNMENT ARROW (4 O’CLOCK)
2 - TANK MARKINGS
3 - LOCKNUT
4 - FUEL TANK
Fig. 16 Locknut Removal/Installation—Typical
1 - SPECIAL TOOL 6856
2 - LOCKNUT
14 - 12
FUEL DELIVERY
AN
FUEL PUMP MODULE (Continued)
FUEL RAIL
DESCRIPTION - 3.9L/5.2L/5.9L
The fuel injector rail is used to attach the fuel
injectors to the engine. It is mounted to the engine
(Fig. 17).
DESCRIPTION - 4.7L
The fuel injector rail is used to mount the fuel
injectors to the engine. It is mounted to the intake
manifold (Fig. 18).
DESCRIPTION - 2.5L
The fuel injector rail is used to mount the fuel
injectors to the engine (Fig. 19). On the 2.5L 4–cylin-
der engine, a fuel damper is located at the front of
the fuel rail (Fig. 19).
OPERATION - 3.9L/5.2L/5.9L
High pressure from the fuel pump is routed to the
fuel rail. The fuel rail then supplies the necessary
fuel to each individual fuel injector.
A fuel pressure test port is located on the fuel rail.
A quick-connect fitting with a safety latch clip is
used to attach the fuel line to the fuel rail.
The fuel rail is not repairable.
CAUTION: The left and right sections of the fuel rail
are connected with a flexible connecting hose. Do
not attempt to separate the rail halves at this con-
necting hose. Due to the design of this connecting
hose, it does not use any clamps. Never attempt to
install a clamping device of any kind to the hose.
When removing the fuel rail assembly for any rea-
son, be careful not to bend or kink the connecting
hose.
OPERATION - 4.7L
High pressure fuel from the fuel pump is routed to
the fuel rail. The fuel rail then supplies the neces-
sary fuel to each individual fuel injector.
A fuel pressure test port is located on the fuel rail
(Fig. 18). A quick-connect fitting with a safety latch
is used to attach the fuel line to the fuel rail.
The fuel rail is not repairable.
Fig. 17 Fuel Rail—3.9/5.2/5.9L Engine—Typical
1 - FUEL RAIL CONNECTING HOSE
2 - FUEL RAIL
3 - MOUNTING BOLTS (4)
Fig. 18 Fuel Injector Rail—4.7L V-8 Engine
1 - MOUNTING BOLTS (4)
2 - INJ.#7
3 - INJ.#5
4 - QUICK-CONNECT FITTING
5 - INJ.#3
6 - FUEL INJECTOR RAIL
7 - INJ.#1
8 - CONNECTOR TUBE
9 - INJ.#2
10 - INJ.#4
11 - INJ.#6
12 - INJ.#8
13 - PRESSURE TEST PORT CAP
AN
FUEL DELIVERY
14 - 13
OPERATION - 2.5L
The fuel injector rail supplies the necessary fuel to
each individual fuel injector.
The fuel damper is used only to help control fuel
pressure pulsations. These pulsations are the result
of the firing of the fuel injectors. It is not used as a
fuel pressure regulator. The fuel pressure regulator is
not mounted to the fuel rail on any engine. It is
located on the fuel tank mounted fuel pump module.
Refer to Fuel Filter/Fuel Pressure Regulator in this
group for information.
The fuel rail is not repairable.
REMOVAL - 2.5L
The fuel damper is not serviced separately.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
THIS PRESSURE MUST BE RELEASED BEFORE
SERVICING FUEL RAIL.
(1) Remove fuel tank filler tube cap.
(2) Perform Fuel System Pressure Release Proce-
dure as described in this Group.
(3) Disconnect negative battery cable from battery.
(4) Remove air tube at top of throttle body. Note:
Some engine/vehicles may require removal of air
cleaner ducts at throttle body.
(5) Remove injector harness electrical connectors
at each injector. Each injector connector should have
a numerical tag attached identifying its correspond-
ing cylinder (Fig. 20). If not, identify each connector
before removal.
(6) Disconnect fuel supply line latch clip and fuel
line at fuel rail. Refer to Quick-Connect Fittings in
this group for procedures.
(7) Disconnect throttle cable at throttle body. Refer
to Throttle Cable Removal/Installation in this group
for procedures.
(8) Disconnect speed control cable at throttle body
(if equipped). Refer to Speed Control Cable in Group
8H, Speed Control System for procedures.
(9) Disconnect automatic transmission cable at
throttle body (if equipped).
(10) Remove cable routing bracket (Fig. 20) at
intake manifold.
(11) Remove nut securing crankshaft position sen-
sor pigtail harness to fuel rail mounting stud.
Remove clamp and harness from fuel rail mounting
stud.
(12) Clean dirt/debris from each fuel injector at
intake manifold.
(13) Remove fuel rail mounting nuts/bolts (Fig.
20).
(14) Remove fuel rail by gently rocking until all
the fuel injectors are out of intake manifold.
Fig. 19 Fuel Injector Rail/Fuel Damper—2.5L Engine
1 - FUEL DAMPER
2 - FUEL INJECTOR
3 - NUMBERED TAG
4 - FUEL RAIL
5 - FUEL RAIL MOUNTING BOLTS/NUTS
6 - TEST PORT
7 - CABLE BRACKET
Fig. 20 Fuel Rail Mounting—2.5L Engine
1 - FUEL DAMPER
2 - FUEL INJECTOR
3 - NUMBERED TAG
4 - FUEL RAIL
5 - FUEL RAIL MOUNTING BOLTS/NUTS
6 - TEST PORT
7 - CABLE BRACKET
14 - 14
FUEL DELIVERY
AN
FUEL RAIL (Continued)
REMOVAL - 3.9L/5.2L/5.9L
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH ENGINE TURNED
OFF). BEFORE SERVICING FUEL RAIL ASSEMBLY,
FUEL SYSTEM PRESSURE MUST BE RELEASED.
To release fuel pressure, refer to Fuel System Pres-
sure Release Procedure in this group.
CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate rail
halves at connecting hose (Fig. 21). Due to the
design of this connecting hose, it does not use any
clamps. Never attempt to install a clamping device
of any kind to hose. When removing fuel rail
assembly for any reason, be careful not to bend or
kink connecting hose.
(1) Remove negative battery cable at battery.
(2) Remove air cleaner.
(3) Perform fuel pressure release procedure.
(4) Remove throttle body from intake manifold.
Refer to Throttle Body removal in this group.
(5) If equipped with air conditioning, remove
A-shaped A/C compressor-to-intake manifold support
bracket (three bolts) (Fig. 22).
(6) Disconnect electrical connectors at all 8 fuel
injectors. To remove connector refer to (Fig. 23). Push
red colored slider away from injector (1). While push-
ing slider, depress tab (2) and remove connector (3)
from injector. The factory fuel injection wiring har-
ness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. If harness is not
tagged, note wiring location before removal.
(7) 3.9L (V-6) engine only: Disconnect electrical
connector at intake manifold air temperature sensor.
Do not remove sensor.
(8) Disconnect fuel tube (line) at side of fuel rail.
Refer to Quick-Connect Fittings for procedures,
(9) Remove remaining fuel rail mounting bolts.
(10) Clean dirt/debris from each fuel injector at
intake manifold.
Fig. 21 Fuel Rail Assembly—3.9/5.2/5.9L Engine—
Typical
1 - FUEL RAIL CONNECTING HOSE
2 - FUEL RAIL
3 - MOUNTING BOLTS (4)
Fig. 22 A/C Compressor Support
1 - AIR CONDITIONING COMPRESSOR SUPPORT BRACKET
2 - MOUNTING BOLTS
Fig. 23 Remove/Install Injector Connector
AN
FUEL DELIVERY
14 - 15
FUEL RAIL (Continued)
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