Dodge Dakota (R1). Manual - part 559

OPERATION

Voltage to operate the electric pump is supplied

through the fuel pump relay.

Fuel is drawn in through a filter at the bottom of

the module and pushed through the electric motor
gearset to the pump outlet.

Check Valve Operation: The pump outlet con-

tains a one-way check valve to prevent fuel flow back
into the tank and to maintain fuel supply line pres-
sure (engine warm) when pump is not operational. It
is also used to keep the fuel supply line full of gaso-
line 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. Refer to the Fuel Pressure Leak
Down Test for more information.

DIAGNOSIS AND TESTING - FUEL PUMP
PRESSURE TEST

Use this test in conjunction with the Fuel Pump

Capacity Test, Fuel Pressure Leak Down Test and
Fuel Pump Amperage Test found elsewhere in this
group.

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.

All fuel systems are equipped with a fuel tank

module mounted, combination fuel filter/fuel pressure
regulator. The fuel pressure regulator is not con-
trolled by engine vacuum.

WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. BEFORE DISCONNECTING FUEL LINE AT
FUEL RAIL, THIS PRESSURE MUST BE RELEASED.
REFER

THE

FUEL

SYSTEM

PRESSURE

RELEASE PROCEDURE.

(1) Remove protective cap at fuel rail test port.

Connect the 0–414 kPa (0-60 psi) fuel pressure gauge
(from gauge set 5069) to test port pressure fitting on
fuel rail (Fig. 7). 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.

(2) Start and warm engine and note pressure

gauge reading. Fuel pressure should be 339 kPa ± 34
kPa (49.2 psi ± 5 psi) at idle.

(3) If engine runs, but pressure is below 44.2 psi,

check for a kinked fuel supply line somewhere
between fuel rail and fuel pump module. If line is not
kinked, but specifications for either the Fuel Pump
Capacity, Fuel Pump Amperage or Fuel Pressure
Leak Down Tests were not met, replace fuel pump
module

assembly.

Refer

Fuel

Pump

Module

Removal/Installation.

(4) If operating pressure is above 54.2 psi, electric

fuel pump is OK, but fuel pressure regulator is defec-
tive. Replace fuel filter/fuel pressure regulator. Refer
to Fuel Filter/Fuel Pressure Regulator Removal/In-
stallation for more information.

(5) Install protective cap to fuel rail test port.

DIAGNOSIS AND TESTING - FUEL PUMP
CAPACITY TEST

Before performing this test, verify fuel pump

pressure. Refer to Fuel Pump Pressure Test.
Use this test in conjunction with the Fuel Pres-
sure Leak Down Test.

(1) Release fuel system pressure. Refer to Fuel

Pressure Release Procedure.

(2) Disconnect fuel supply line at fuel rail. Refer to

Quick-Connect Fittings. Some engines may require
air cleaner housing removal before line disconnection.

Fig. 7 Fuel Pressure Test Gauge (Typical Gauge

Installation at Test Port)

1 - SERVICE (TEST) PORT
2 - FUEL PRESSURE TEST GAUGE
3 - FUEL RAIL

14 - 8

FUEL DELIVERY

FUEL PUMP (Continued)

(3) 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.

(4) Connect

correct

Fuel

Line

Pressure

Test

Adapter Tool Hose into disconnected fuel supply line.
Insert other end of Adaptor Tool Hose into a gradu-
ated container.

(5) Remove fuel fill cap.
(6) To activate fuel pump and pressurize system,

obtain DRB

t scan tool and actuate ASD Fuel System

Test.

(7) A good fuel pump will deliver at least 1/4 liter

of fuel in 7 seconds. Do not operate fuel pump for
longer than 7 seconds with fuel line disconnected as
fuel pump module reservoir may run empty.

(a) If capacity is lower than specification, but

fuel pump can be heard operating through fuel fill
cap opening, check for a kinked/damaged fuel sup-
ply line somewhere between fuel rail and fuel
pump module.

(b) If line is not kinked/damaged, and fuel pres-

sure is OK, but capacity is low, replace fuel filter/
fuel pressure regulator. The filter/regulator may be
serviced separately on certain applications. Refer
to Fuel Filter/Fuel Pressure Regulator Removal/In-
stallation for additional information.

replace fuel pump module assembly. Refer to Fuel
Pump Module Removal/Installation.

DIAGNOSIS AND TESTING - FUEL PUMP
AMPERAGE TEST

This amperage (current draw) test is to be done in

conjunction with the Fuel Pump Pressure Test, Fuel
Pump Capacity Test and Fuel Pressure Leak Down
Test. Before performing the amperage test, be sure
the temperature of the fuel tank is above 50° F (10°
C).

The DRB

t Scan Tool along with the DRB Low Cur-

rent Shunt (LCS) adapter (Fig. 8) and its test leads
will be used to check fuel pump amperage specifica-
tions.

(1) Be sure fuel tank contains fuel before starting

test. If tank is empty or near empty, amperage read-
ings will be incorrect.

(2) Obtain LCS adapter.
(3) Plug cable from LCS adapter into DRB scan

tool at SET 1 receptacle.

(4) Plug DRB into vehicle 16–way connector (data

link connector).

(5) Connect (-) and (+) test cable leads into LCS

adapter receptacles. Use 10 amp (10A +) receptacle
and common (-) receptacles.

(6) Gain access to MAIN MENU on DRB screen.
(7) Press DVOM button on DRB.

(8) Using left/right arrow keys, highlight CHAN-

NEL 1 function on DRB screen.

(9) Press ENTER three times.
(10) Using up/down arrow keys, highlight RANGE

on DRB screen (screen will default to 2 amp scale).

(11) Press ENTER to change 2 amp scale to 10

amp scale. This step must be done to prevent
damage to DRB scan tool or LCS adapter
(blown fuse).

(12) Remove cover from Power Distribution Center

(PDC).

(13) Remove fuel pump relay from PDC. Refer to

label on PDC cover for relay location.

WARNING: BEFORE PROCEEDING TO NEXT STEP,
NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI-
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND
FUEL SYSTEM COMPONENTS ARE CONNECTED.

CAUTION: To prevent possible damage to the vehi-
cle electrical system and LCS adapter, the test
leads must be connected into relay cavities exactly
as shown in following steps.

Depending upon vehicle model, year or engine con-

figuration, three different types of relays may be
used: Type-1, type-2 and type–3.

Fig. 8 Low Current Shunt

1 - LOW CURRENT SHUNT ADAPTER
2 - PLUG TO DRB
3 - TEST LEAD RECEPTACLES

FUEL DELIVERY

14 - 9

FUEL PUMP (Continued)

(14) If equipped with type–1 relay (Fig. 9), attach

test leads from LCS adapter into PDC relay cavities
number 30 and 87. For location of these cavities,
refer to numbers stamped to bottom of relay (Fig. 9).

(15) If equipped with type–2 relay (Fig. 10),

attach test leads from LCS adapter into PDC relay
cavities number 30 and 87. For location of these cav-
ities, refer to numbers stamped to bottom of relay
(Fig. 10).

(16) If equipped with type–3 relay (Fig. 11),

attach test leads from LCS adapter into PDC relay
cavities number 3 and 5. For location of these cavi-
ties, refer to numbers stamped to bottom of relay
(Fig. 11).

(17) When LCS adapter test leads are attached

into relay cavities, fuel pump will be activated.
Determine fuel pump amperage on DRB screen.
Amperage should be below 10.0 amps. If amperage is
below 10.0 amps, and specifications for the Fuel
Pump Pressure, Fuel Pump Capacity and Fuel Pres-
sure Leak Down tests were met, the fuel pump mod-
ule is OK.

(18) If amperage is more than 10.0 amps, replace

fuel pump module assembly. The electric fuel pump
is not serviced separately.

(19) Disconnect test leads from relay cavities

immediately after testing.

Fig. 9 FUEL PUMP RELAY - TYPE 1

TERMINAL LEGEND

NUMBER

IDENTIFICATION

COMMON FEED

COIL GROUND

COIL BATTERY

NORMALLY OPEN

87A

NORMALLY CLOSED

Fig. 10 FUEL PUMP RELAY - TYPE 2

TERMINAL LEGEND

NUMBER

IDENTIFICATION

COMMON FEED

COIL GROUND

COIL BATTERY

NORMALLY OPEN

87A

NORMALLY CLOSED

Fig. 11 FUEL PUMP RELAY - TYPE 3

TERMINAL LEGEND

NUMBER

IDENTIFICATION

COIL BATTERY

COIL GROUND

COMMON FEED

NORMALLY CLOSED

NORMALLY OPEN

14 - 10

FUEL DELIVERY

FUEL PUMP (Continued)

FUEL PUMP MODULE

DESCRIPTION

The fuel pump module on all models/all engines is

installed in the top of the fuel tank (Fig. 12) or (Fig.
13). The fuel pump module contains the following
components :

• A combination fuel filter/fuel pressure regulator

• Electric fuel pump

• Fuel pump reservoir

• A separate in-tank fuel filter (at bottom of mod-

ule)

• Fuel gauge sending unit (fuel level sensor)

• Fuel supply line connection at filter/regulator

• A threaded locknut to retain pump module to

fuel tank

• A rubber gasket between tank flange and pump

module

The fuel gauge sending unit (fuel level sensor), and

pick-up filter (at bottom of module) may be serviced
separately. If the electrical fuel pump requires ser-
vice, the entire fuel pump module must be replaced.

OPERATION

Refer to Fuel Pump, Fuel Filter/Fuel Pressure Reg-

ulator and Fuel Gauge Sending Unit.

REMOVAL

WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING FUEL PUMP MODULE, FUEL
SYSTEM PRESSURE MUST BE RELEASED.

(1) Drain fuel tank and remove tank. Refer to Fuel

Tank Removal.

(2) Thoroughly wash and clean area around pump

module to prevent contaminants from entering tank.

(3) The fuel pump module locknut is threaded onto

fuel tank (Fig. 14) or (Fig. 15). Install Special Tool
6856 to fuel pump module locknut and remove lock-
nut (Fig. 16).

(4) Remove module from fuel tank.

Fig. 12 Fuel Tank/Fuel Pump Module—2 Door

Models

1 - FILL HOSE
2 - VENT HOSE
3 - ROLLOVER VALVE
4 - LOCKNUT
5 - FUEL PUMP MODULE
6 - FUEL TANK
7 - FUEL FILTER/FUEL PRESSURE REGULATOR

Fig. 13 Fuel Tank/Fuel Pump Module—4 Door

Models

1 - FUEL FILTER/FUEL PRESSURE REGULATOR
2 - ROLLOVER VALVE
3 - FUEL TANK SHIELD
4 - LOCKNUT
5 - FUEL PUMP MODULE
6 - ROLLOVER VALVE
7 - FUEL TANK
8 - FILL HOSE
9 - VENT HOSE
10 - PIGTAIL HARNESS

FUEL DELIVERY

14 - 11

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