Dodge Viper SRT-10 (ZB). Manual — part 193
FUEL DELIVERY
DESCRIPTION
FUEL DELIVERY SYSTEM
The fuel delivery system consists of: the electric
fuel pump, fuel filter, fuel pressure regulator, fuel
tubes/lines/hoses, fuel rail, fuel injectors, fuel tank,
accelerator pedal and throttle cable.
The in-tank fuel pump module contains the fuel
pump, level sensor, and fuel pressure regulator. The
pump, and regulator are serviced as part of the fuel
pump module. Refer to Fuel Pump Module.
LONG-TERM STORAGE
When storing your vehicle for long periods, leave
the fuel tank and fuel system full of fuel. For further
information about long-term vehicle storage, refer to
the Lubrication and Maintenance section.
OPERATION - FUEL DELIVERY SYSTEM
A fuel return system is used on all models. Fuel is
returned through the fuel pressure regulator within
the fuel pump module.
The fuel tank assembly consists of: the fuel tank,
filler tube, fuel gauge sending unit/electric fuel pump
module, rollover valve, ORVR control valve, fuel fill
check valve, and a pressure-vacuum filler cap.
Also to be considered part of the fuel system is the
evaporation control system. This is designed to
reduce the emission of fuel vapors into the atmo-
sphere. The description and function of the Evapora-
tive Control System is found in the Emission Control
Systems.
STANDARD PROCEDURE
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE
(1) Remove Fuel Pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(2) Start and run engine until it stalls.
(3) Attempt restarting engine until it will no
longer run.
(4) Turn ignition key to OFF position.
(5) Return fuel pump relay to PDC.
(6) One or more Diagnostic Trouble Codes (DTC’s)
may have been stored in PCM memory due to fuel
pump relay removal. The DRB III
t scan tool must be
used to erase a DTC.
DRAINING FUEL TANK
(1) Release fuel system pressure. Refer to Fuel
Pressure Release Procedure in this section.
(2) Remove the fuel pump module, refer to the fuel
pump module removal/installation in this section.
(3) Drain fuel from fuel tank into siphoning tank.
Refer to the siphoning tank Manufacturer’s Instruc-
tions.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
379 kpa ±34 kpa (55 psi ± 5 psi)
TORQUE
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Accelerator Pedal to Dash
Nuts
12
105
Fuel Pump Module Lock-
nut
55
40
Fuel Tank Strap Bolts
22.5
200
Fuel Rail Bolts
12
105
Ignition Coil Mounting
Bolts
11
95
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FUEL DELIVERY
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SPECIAL TOOLS
FUEL
FUEL FILTER
DESCRIPTION
The fuel filter mounts inside frame rail on the
drivers side of vehicle near the rear tire.
REMOVAL
(1) Release fuel pressure, refer to the fuel release
procedure in this section.
(2) Remove the battery cover and disconnect nega-
tive battery cable.
(3) Raise vehicle and support.
(4) Remove fuel tubes from fuel filter. Refer to
quick-connect fittings in this section.
(5) Remove the fuel filter mounting bolt (Fig. 1).
(6) Remove the fuel filter from mounting clamp.
INSTALLATION
(1) Install the fuel filter with mounting clamp.
(2) Install the fuel filter mounting bolt.
(3) Install fuel tubes to fuel filter. Refer to quick-
connect fittings in this section.
(4) Lower vehicle.
(5) Connect negative battery cable and install the
battery cover.
Test Kit, Fuel
Adapters, Fuel Pressure Test—6539 and/or 6631
Spanner Wrench—6856
Fuel Line Adapter 1/4
O2S (OXYGEN SENSOR) REMOVAL/INSTALLER-
C4907
Oxygen sensor tool
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FUEL DELIVERY
14 - 3
FUEL DELIVERY (Continued)
FUEL LEVEL SENSOR
DESCRIPTION
The level sensor is attached to the side of the fuel
pump module. The level sensor consists of a float, an
arm, and a variable resistor.
OPERATION
As the fuel level increases, the float and arm move
up. This decreases the sending unit resistance, caus-
ing the fuel gauge on the instrument panel to read
full. The fuel level sensor (fuel gauge sending unit) is
monitored by the BCM to indicate fuel level. The
BCM sends a raw fuel message to the PCM and to a
dampened fuel message to the cluster. The PCM will
not set misfire and fuel system monitor trouble codes
if the fuel level is less than approximately 15 percent
of its rated capacity. The BCM has open and short
circuit detection on the fuel level sensor input.
REMOVAL
Remove fuel pump module. Refer to Fuel Pump
Module in this section (Fig. 2).
(1) Depress retaining tab and remove the fuel
pump/level sensor connector from the bottom of the
fuel pump module electrical connector (Fig. 3).
(2) Pull out the locking wedge (Fig. 4).
(3) Using a small screwdriver lift locking finger
away from terminal and push terminal out of connec-
tor (Fig. 5).
(4) Push level sensor signal and ground terminals
out of the connector (Fig. 5).
(5) Push down on the tab and push level sensor
down and out of channel on the side of the pump
module (Fig. 6).
INSTALLATION
(1) Insert level sensor wires into bottom of opening
in module.
(2) Wrap wires into groove in back of level sensor
(Fig. 7).
(3) While feeding wires into guide grooves, slide
level sensor up into channel until it snaps into place.
Ensure tab at bottom of sensor locks in place.
(4) Install level sensor wires in connector. Push
the wires up through the connector and then pull
them down until they lock in place. Ensure signal
and ground wires are installed in the correct posi-
tion.
(5) Install locking wedge on connector.
Fig. 1 FUEL FILTER LOCATION
Fig. 2 Fuel Pump Module
Fig. 3 Fuel Pump/Level Sensor Electrical Connector
1 - ELECTRICAL CONNECTOR
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FUEL DELIVERY
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FUEL FILTER (Continued)
(6) Push connector up into bottom of fuel pump
module electrical connector.
(7) Install fuel pump module. Refer to Fuel Pump
Module in this section.
FUEL TUBES/LINES/HOSES
AND CLAMPS
DESCRIPTION - FUEL TUBES/LINES/HOSES
AND CLAMPS
Also refer to Quick-Connect Fittings.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
The lines/tubes/hoses used on fuel injected vehicles
are of a special construction. This is due to the
higher fuel pressures and the possibility of contami-
nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, only those marked EFM/EFI
may be used.
If equipped: The hose clamps used to secure rub-
ber hoses on fuel injected vehicles are of a special
rolled edge construction. This construction 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 types of clamps may
cut into the hoses and cause high-pressure fuel leaks.
Use new original equipment type hose clamps.
Fig. 4 Wedge Lock
Fig. 5 Wire Terminal Locking Finger
1 - LOCKING FINGER
2 - WIRE TERMINAL
Fig. 6 Fuel Level Sensor
1 - FUEL LEVER SENSOR
Fig. 7 Groove in Back Side of Level Sensor
1 - WIRING GROOVE
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FUEL DELIVERY
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FUEL LEVEL SENSOR (Continued)
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