Dodge Dakota (R1). Manual - part 557

AUTOMATIC TRANSMISSION
CROSSMEMBER R-1

REMOVAL

(1) Disconnect and isolate the negative battery

cable.

(2) Remove the upper fan shroud retaining bolts.
(3) Raise and support the vehicle.
(4) Remove the lower fan shroud retaining bolts.
(5) Support the transmission with a jack stand.
(6) Remove the transmission mount fasteners and

slightly raise the transmission.

(7) Remove the transmission mount from the

transmission mount adapter bracket.

(8) Remove the exhaust system support bracket

retaining nut.

(9) Remove the fuel line support bracket retaining

bolt from the left side of the transmission crossmem-
ber.

(10) Remove the eight crossmember retaining bolts

from the frame rails.

(11) Significant force will be required to remove

the crossmember from the frame rails. Remove the
crossmember from between the frame rails.

INSTALLATION

(1) Install the crossmember between the frame

rails.

(2) Install the eight crossmember retaining bolts.

Torque to 65 N·m (48 ft. lbs.).

(3) Install the transmission mount on the adapter

bracket. Torque to 47 N·m (35 ft. lbs.).

(4) Lower the transmission and install the trans-

mission mount retaining fasteners. Torque to 47 N·m
(35 ft. lbs.).

(5) Install the exhaust system support bracket

retaining nut.

(6) Install the fuel line support bracket on the left

side of the transmission crossmember.

(7) Remove the jack stand from the transmission.
(8) Install the fuel line clip on the crossmember.
(9) Install the lower fan shroud retaining bolts.
(10) Lower the vehicle.
(11) Install the upper fan shroud retaining bolts.
(12) Connect the negative battery cable.

13a - 6

FRAME & BUMPERS

FUEL SYSTEM

TABLE OF CONTENTS

page

FUEL DELIVERY

. . . . . . . . . . . . . . . . . . . . . . . . . . 1

FUEL INJECTION

. . . . . . . . . . . . . . . . . . . . . . . . 26

FUEL DELIVERY

TABLE OF CONTENTS

page

FUEL DELIVERY

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 2

FUEL PRESSURE LEAK DOWN TEST . . . . . . . . 2

STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . . 3

FUEL SYSTEM PRESSURE RELEASE . . . . . . . . 3

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUEL FILTER/PRESSURE REGULATOR

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUEL LEVEL SENDING UNIT / SENSOR

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 6

FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . 6

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FUEL LINES

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FUEL PUMP

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 8

FUEL PUMP PRESSURE TEST . . . . . . . . . . . . . 8
FUEL PUMP CAPACITY TEST . . . . . . . . . . . . . . 8
FUEL PUMP AMPERAGE TEST . . . . . . . . . . . . . 9

FUEL PUMP MODULE

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12

FUEL RAIL

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 17

FUEL TANK

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21

INLET FILTER

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 21

QUICK CONNECT FITTING

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . . 22

QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . 22

ROLLOVER VALVE

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 25

FUEL DELIVERY

DESCRIPTION

The fuel delivery system consists of:
• the fuel pump module containing the electric

fuel pump, fuel filter/fuel pressure regulator, fuel

gauge sending unit (fuel level sensor) and a separate
fuel filter located at bottom of pump module

• fuel tubes/lines/hoses

• quick-connect fittings

• fuel injector rail

• fuel injectors

• fuel tank

• fuel tank filler/vent tube assembly

FUEL SYSTEM

14 - 1

• fuel tank filler tube cap

• accelerator pedal

• throttle cable

OPERATION

Fuel is returned through the fuel pump module

and back into the fuel tank through the fuel filter/
fuel pressure regulator. A separate fuel return line
from the engine to the tank is not used.

The fuel tank assembly consists of: the fuel tank,

fuel pump module assembly, fuel pump module lock-
nut/gasket, and rollover valve (refer to rollover valve
for information).

A fuel filler/vent tube assembly using a pressure/

vacuum, 1/4 turn fuel filler cap is used. The fuel
filler tube contains a flap door located below the fuel
fill 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 Emission Control
Systems.

Both fuel filters (at bottom of fuel pump module

and within fuel pressure regulator) are designed for
extended service. They do not require normal sched-
uled maintenance. Filters should only be replaced if
a diagnostic procedure indicates to do so.

DIAGNOSIS AND TESTING - FUEL PRESSURE
LEAK DOWN TEST

Use this test in conjunction with the Fuel Pump

Pressure Test and Fuel Pump Capacity Test.

Check Valve Operation: The electric fuel pump

outlet contains a one-way check valve to prevent fuel
flow back into the tank and to maintain fuel supply
line pressure (engine warm) when pump is not oper-
ational. It is also used to keep the fuel supply line
full of gasoline when pump is not operational. After
the vehicle has cooled down, fuel pressure may drop
to 0 psi (cold fluid contracts), but liquid gasoline will
remain in fuel supply line between the check valve
and

fuel

injectors.

Fuel

pressure

that

has

dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the elec-
tric fuel pump is activated, fuel pressure should
immediately (1–2 seconds) rise to specification.

Abnormally long periods of cranking to restart a

hot engine that has been shut down for a short
period of time may be caused by:

• Fuel pressure bleeding past a fuel injector(s).

• Fuel pressure bleeding past the check valve in

the fuel pump module.

(1) Disconnect the fuel inlet line at fuel rail. Refer

to Fuel Tubes/Lines/Hoses and Clamps for proce-

dures. On some engines, air cleaner housing removal
may be necessary before fuel line disconnection.

(2) Obtain correct Fuel Line Pressure Test Adapter

Tool Hose. Tool number 6539 is used for 5/16” fuel
lines and tool number 6631 is used for 3/8” fuel lines.

(3) Connect

correct

Fuel

Line

Pressure

Test

Adapter Tool Hose between disconnected fuel line
and fuel rail (Fig. 1).

(4) Connect the 0-414 kPa (0-60 psi) fuel pressure

test gauge (from Gauge Set 5069) to the test port on
the appropriate Adaptor Tool. The DRB

t III Scan

Tool along with the PEP module, the 500 psi
pressure transducer, and the transducer-to-test
port adapter may also be used in place of the
fuel pressure gauge.

The fittings on both tools must be in good

condition and free from any small leaks before
performing the proceeding test.

(5) Start engine and bring to normal operating

temperature.

(6) Observe test gauge. Normal operating pressure

should be 339 kPa +/–34 kPa (49.2 psi +/–5 psi).

(7) Shut engine off.
(8) Pressure should not fall below 30 psi for five

minutes.

Fig. 1 Connecting Adapter Tool—Typical

1 - VEHICLE FUEL LINE
2 - TEST PORT “T”
3 - SPECIAL TOOL 6923, 6631, 6541 OR 6539
4 - FUEL PRESSURE TEST GAUGE
5 - FUEL LINE CONNECTION AT RAIL
6 - FUEL RAIL

14 - 2

FUEL DELIVERY

FUEL DELIVERY (Continued)

(9) If pressure falls below 30 psi, it must be deter-

mined if a fuel injector, the check valve within the
fuel pump module, or a fuel tube/line is leaking.

(10) Again, start engine and bring to normal oper-

ating temperature.

(11) Shut engine off.
(12) Testing for fuel injector or fuel rail leak-

age: Clamp off the rubber hose portion of Adaptor
Tool between the fuel rail and the test port “T” on
Adapter Tool. If pressure now holds at or above 30
psi, a fuel injector or the fuel rail is leaking.

(13) Testing for fuel pump check valve, filter/

regulator check valve or fuel tube/line leakage:
Clamp off the rubber hose portion of Adaptor Tool
between the vehicle fuel line and test port “T” on
Adapter Tool. If pressure now holds at or above 30
psi, a leak may be found at a fuel tube/line. If no
leaks are found at fuel tubes or lines, one of the
check valves in either the electric fuel pump or filter/
regulator may be leaking.

Note: A quick loss of pressure usually indicates a

defective check valve in the filter/regulator. A slow
loss of pressure usually indicates a defective check
valve in the electric fuel pump.

The electric fuel pump is not serviced separately.

Replace the fuel pump module assembly. The filter/reg-
ulator may be replaced separately on certain applica-
tions. Refer to Fuel Filter/Fuel Pressure Regulator
Removal/Installation for additional information.

STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE

Use following procedure if the fuel injector

rail is, or is not equipped with a fuel pressure
test port.

(1) Remove fuel fill cap.

(2) Remove fuel pump relay from Power Distribu-

tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.

(3) Start and run engine until it stalls.
(4) Attempt restarting engine until it will no

longer run.

(5) Turn ignition key to OFF position.

CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.

(6) Unplug connector from any fuel injector.
(7) Attach one end of a jumper wire with alligator

clips (18 gauge or smaller) to either injector terminal.

(8) Connect other end of jumper wire to positive

side of battery.

(9) Connect one end of a second jumper wire to

remaining injector terminal.

CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.

(10) Momentarily touch other end of jumper wire

to negative terminal of battery for no more than a
few seconds.

(11) Place a rag or towel below fuel line quick-con-

nect fitting at fuel rail.

(12) Disconnect quick-connect fitting at fuel rail.

Refer to Quick-Connect Fittings.

(13) Return fuel pump relay to PDC.
(14) One or more Diagnostic Trouble Codes (DTC’s)

may have been stored in PCM memory due to fuel
pump relay removal. The DRB

t scan tool must be

used to erase a DTC.

SPECIFICATIONS

FUEL SYSTEM PRESSURE

339 kPa +/- 34 kPa (49.2 psi +/- 2 psi).

TORQUE - FUEL DELIVERY

DESCRIPTION

N-m

Ft. Lbs.

In. Lbs.

Accelerator Pedal Bracket Mounting Nuts

Fuel Pump Module Locknut

Fuel Rail Mounting Bolts - 3.9L/5.2L/5.9L

200

Fuel Rail Mounting Bolts - 4.7L

Fuel Rail Mounting Bolts - 2.5L

100

Fuel Tank Mounting Nuts

27-54

20-40

Fuel Hose Clamps

FUEL DELIVERY

14 - 3

FUEL DELIVERY (Continued)

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