Dodge Viper SRT-10 (ZB). Manual — part 194
STANDARD PROCEDURE - HOSES AND
CLAMPS
Inspect all hose connections (clamps and quick con-
nect fittings) for completeness and leaks. Replace
cracked, scuffed, or swelled hoses. Replace hoses that
rub against other vehicle components or show sign of
wear.
Fuel injected vehicles use specially constructed
hoses. When replacing hoses, only use hoses marked
EFM/EFI.
When installing hoses, ensure that they are routed
away from contact with other vehicle components
that could rub against them and cause failure. Avoid
contact with clamps or other components that cause
abrasions or scuffing. Ensure that rubber hoses are
properly routed and avoid heat sources.
The hose clamps have rolled edges to prevent the
clamp from cutting into the hose. Only use clamps
that are original equipment or equivalent. Other
types of clamps may cut into the hoses and cause
high pressure fuel leaks. Tighten hose clamps to 1
N·m (9 in. lbs.) torque.
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.
Replace as necessary.
Avoid contact of any fuel tubes/hoses with other
vehicle components that could cause abrasions or
scuffing. Be sure that the plastic fuel lines/tubes are
properly routed to prevent pinching and to avoid heat
sources.
FUEL PRESSURE REGULATOR
DESCRIPTION
A fuel pressure regulator is used on all gas pow-
ered engines. It is located inside the fuel pump mod-
ule. It contains a diaphragm, calibrated springs and
a fuel return valve.
OPERATION
The pressure regulator is a mechanical device that
is calibrated to maintain fuel system operating pres-
sure of approximately 379 kPa (55 psi) at the fuel
injectors.
It contains a diaphragm, calibrated springs and a
fuel return valve.
Fuel is supplied to the regulator by the electric fuel
pump through an opening tube at the bottom of reg-
ulator.
The fuel pump module contains a check valve to
maintain some fuel pressure when the engine is not
operating. This will help to start the engine.
If fuel pressure at the pressure regulator exceeds
approximately 56 psi, an internal diaphragm closes
and excess fuel pressure is routed back into the tank
through the pressure regulator. A separate fuel
return line is not used with any gas powered engine.
The pressure regulator is a mechanical device that
is NOT controlled by the PCM or engine vacuum.
REMOVAL
The fuel pressure regulator is part of the fuel
pump module (Fig. 8). Remove the fuel pump module
from the fuel tank to access the fuel pressure regula-
tor. Refer to the Fuel Pump Module removal in this
section.
WARNING: FUEL SYSTEM PRESSURE MUST BE
RELEASED BEFORE SERVICING ANY FUEL SYS-
TEM COMPONENT. PERFORM THE FUEL SYSTEM
PRESSURE RELEASE PROCEDURE.
(1) Spread tangs on pressure regulator retainer
(Fig. 8).
(2) Pry fuel pressure regulator out of housing.
(3) Ensure that the O-ring was removed with reg-
ulator (Fig. 9).
Fig. 8 Fuel Pressure Regulator
1 - FUEL PRESSURE REGULATOR
14 - 6
FUEL DELIVERY
ZB
FUEL TUBES/LINES/HOSES AND CLAMPS (Continued)
INSTALLATION
The fuel pressure regulator is part of the fuel
pump module. Remove the fuel pump module from
the fuel tank to access the fuel pressure regulator.
Refer to the Fuel Pump Module removal in this sec-
tion.
(1) Lightly lubricate the O-ring with clean engine
oil and place them into opening in pump module.
(2) Push regulator into opening in pump module.
(3) Push regulator retainer over tabs on housing.
(4) Install Fuel Pump Module, refer to the Fuel
Pump Module installation in this section.
ELECTRIC FUEL PUMP
DESCRIPTION
The electric fuel pump is located in and is part of
the fuel pump module. It is a positive displacement,
gerotor type, immersible pump with a permanent
magnet electric motor. The fuel pump module is sus-
pended in fuel in the fuel tank.
OPERATION
The pump draws fuel through a strainer and
pushes it through the motor to the outlet. The pump
contains a check valve. The valve, in the pump out-
let, maintains pump pressure during engine off con-
ditions. The fuel pump relay provides voltage to the
fuel pump. The fuel pump has a maximum dead-
headed pressure output of approximately 880 kPa
(130 psi). The regulator adjusts fuel system pressure
to approximately 379 kPa (55 psi).
FUEL PUMP ELECTRICAL CONTROL
Voltage to operate the electric pump is supplied
through the fuel pump relay. For an electrical opera-
tional description of the fuel pump refer to fuel Pump
Relay—PCM Output.
STANDARD PROCEDURE - FUEL PUMP
REPLACEMENT
The electric fuel pump is not serviceable. If the
fuel pump or electrical wiring harness needs replace-
ment, the complete fuel pump module must be
replaced. Perform the Fuel System Pressure Release
procedure before servicing the fuel pump.
FUEL PUMP MODULE
DESCRIPTION
The fuel pump module contains the fuel pump, fuel
reservoir, level sensor, inlet strainer, and fuel pres-
sure regulator. The level sensor is the only service-
able items. If the fuel pump or fuel pressure
regulator requires service, replace the fuel pump
module.
REMOVAL
(1) Release fuel system pressure. Refer to Fuel
Pressure Release Procedure in this section.
(2) Remove the battery cover and disconnect nega-
tive battery cable.
(3) Remove the convertible top fasteners (15 nuts)
(Fig. 10) and (Fig. 11).
Fig. 9 Fuel Pressure Regulator
1 - FUEL PRESSURE REGULATOR
Fig. 10 CONVERTIBLE TOP ATTACHMENT
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FUEL DELIVERY
14 - 7
FUEL PRESSURE REGULATOR (Continued)
(4) Lift the top up and disconnect the heated back
glass electrical connector (Fig. 12) from both sides of
the glass.
(5) Pull top forward and out of the way.
(6) Roll deck lid carpet forward and out of the way.
NOTE: Be careful the sealer on the cover will make
it difficult to remove the cover.
(7) Remove the 4 rivets from the fuel pump mod-
ule cover (Fig. 13) and (Fig. 14). You may have to
knock out the center pin with a punch.
(8) Using a scraper or long knife cut the sealer
under the cover to remove it from the vehicle.
(9) Remove the foam block from the top of the fuel
pump module (Fig. 15) and (Fig. 16).
(10) Unlock and disconnect the electrical connector
from the fuel pump module.
(11) Clean the area round the fuel pump module.
(12) Mark fuel pump module location on tank.
(13) Disconnect the fuel line, wrap shop towels
around ends of fuel supply line (Fig. 17).
(14) Use Special Tool #6856 to remove fuel pump
module locknut (Fig. 18).
(15) Lift module up to remove being careful not to
spill the residual fuel that is left in it. The float arm
of the level sensor catches on the inside of the fuel
tank while removing the module. Tilt the module
assembly to one side while removing it. Discard old
seal.
Fig. 11 CONVERTIBLE FASTENER
Fig. 12 BACK GLASS ELECTRICAL CONNECTOR
Fig. 13 FUEL PUMP MODULE COVER
Fig. 14 REMOVAL OF COVER AND RIVETS
14 - 8
FUEL DELIVERY
ZB
FUEL PUMP MODULE (Continued)
INSTALLATION
(1) Wipe seal area of tank clean and place a new
seal in position in the tank opening.
(2) Install gasket on fuel tank.
(3) Position the locknut over the fuel pump mod-
ule.
(4) Seat Fuel Pump Module in tank by pushing
down on it, align the fuel pump module with mark on
tank. Make sure that the level sensor float arm is
forward in the tank.
(5) Hand tighten the lock nut, then torque to 55
N·m (40 ft. lbs.) using Special tool #6856.
CAUTION: Over tightening the pump lock ring may
result in a leak.
(6) Connect and lock the electrical connector to the
fuel pump module.
(7) Connect fuel line to the fuel pump module.
Refer to Quick-Connect Fittings in the Fuel Delivery
Section of this group.
(8) Fill fuel tank.
(9) Connect negative battery cable.
(10) Use the DRBIII
t Scan Tool ASD Fuel System
Test to pressurize the fuel system. Check for leaks.
(11) Disconnect negative battery cable.
(12) Install the foam block to the top of the fuel
pump module (Fig. 15) and (Fig. 16).
(13) Install the fuel pump module cover using
sealer and rivets.
(14) Roll deck lid carpet back in place.
Fig. 15 PUMP MODULE FOAM BLOCK
Fig. 16 FOAM BLOCK REMOVAL/INSTALL
Fig. 17 ELECTRICAL & FUEL CONNECTION
Fig. 18 FUEL PUMP MODULE LOCK RING
ZB
FUEL DELIVERY
14 - 9
FUEL PUMP MODULE (Continued)
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