Fuel Delivery: Other Dodge Durango II

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 Distribution 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 cylinder 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-connect fitting at fuel rail.
12. Disconnect quick-connect fitting at fuel rail. Refer to «FITTING, QUICK CONNECT»(ref-564649-S03316152772013070500000) .
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. A diagnostic scan tool must be used to erase a DTC.

FUEL SYSTEM PRESSURE

58 psi +/- 2 psi

STANDARD PROCEDURE - QUICK-CONNECT FITTINGS

Different types of quick-connect fittings are used to attach the various fuel system components, lines and tubes. These are: a single-button type, a two-button type, a pinch type, a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Some may require the use of a special tool for disconnection and removal.

DISCONNECTING

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

1. Perform «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(ref-564649-S02344868012013070500000) .
2. Disconnect negative battery cable from battery.
3. Clean fitting of any foreign material before disassembly.
4. Single-Button Type Fitting: This type of fitting is equipped with a single push-button (2) located on the quick-connect fitting.
5. The push-button is attached to two internal latches (1). To disconnect, press on push-button with your thumb and unlatch fitting from fuel line. Special tools are not required for disconnection. DO NOT ATTEMPT TO PRY OR PULL UP ON PUSH-BUTTON. LATCHES WILL BE BROKEN.
6. Perform «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(ref-564649-S02344868012013070500000) .
7. Disconnect negative battery cable from battery.
8. Clean fitting of any foreign material before disassembly.
9. 2-Button Type Fitting: This type of fitting (1) is equipped with a push-button located on each side of quick-connect fitting (2). Press on both buttons simultaneously for removal. Special tools are not required for disconnection.
10. Pinch-Type Fitting: This fitting (1) is equipped with two finger tabs (2). Pinch both tabs together while removing fitting. Special tools are not required for disconnection.
11. Single-Tab Type Fitting: This type of fitting (3) is equipped with a single pull tab (1). The tab is removable. After tab is removed, quick-connect fitting can be separated from fuel system component. Special tools are not required for disconnection.
12. Press release tab on side of fitting to release pull tab (1). If release tab is not pressed prior to releasing pull tab, pull tab will be damaged.
13. While pressing release tab on side of fitting, use screwdriver (2) to pry up pull tab.
14. Raise pull tab until it separates from quick-connect fitting.
15. Two-Tab Type Fitting: This type of fitting (2) is equipped with tabs located on both sides of fitting (1). The tabs are supplied for disconnecting quick-connect fitting from component being serviced. To disconnect quick-connect fitting, squeeze plastic retainer tabs (1) against sides of quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. Pull fitting from fuel system component being serviced. The plastic retainer will remain on component being serviced after fitting is disconnected. The o-rings and spacer will remain in quick-connect fitting connector body.
16. Plastic Retainer Ring Type Fitting: This type of fitting can be identified by the use of a full-round plastic retainer ring (4) usually black in color. To release fuel system component from quick-connect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting (6). With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary.
17. Latch Clips - Type 1: Depending on vehicle model and engine, 2 different types of safety latch clips are used. Type-1 (4) is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/fuel rail connection, or to join fuel lines together.
18. Pry up on latch clip with a screwdriver (3).
19. Slide latch clip toward fuel rail while lifting with screwdriver.
20. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (1). Use tool to release locking fingers in end of line.
21. With special tool still inserted, pull fuel line from fuel rail.
22. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line.
23. Disconnect quick-connect fitting from fuel system component being serviced.
24. Latch Clips - Type 2 : Depending on vehicle model and engine, 2 different types of safety latch clips are used. Type-1 is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/fuel rail connection, or to join fuel lines together.
25. Type 2: Separate and unlatch 2 small arms (1) on end of clip and swing away from fuel line.
26. Slide latch clip toward fuel rail while lifting with screwdriver.
27. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (1). Use tool to release locking fingers in end of line.
28. With special tool still inserted, pull fuel line from fuel rail.
29. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line.
30. Disconnect quick-connect fitting from fuel system component being serviced.

CONNECTING

1. Inspect quick-connect fitting body and fuel system component for damage. Replace as necessary.
2. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil.
3. Insert quick-connect fitting into fuel tube or fuel system component until built-on stop on fuel tube or component rests against back of fitting.
4. Continue pushing until a click is felt.
5. Single-tab type fitting: Push new tab down until it locks into place in quick-connect fitting.
6. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.).
7. Latch Clip Equipped: Install latch clip (snaps into position). If latch clip will not fit, this indicates fuel line is not properly installed to fuel rail (or other fuel line). Recheck fuel line connection.
8. Connect negative cable to battery.
9. Start engine and check for leaks.

Electric Fuel Pump

The electric fuel pump is located inside of the fuel pump module. A 12 volt, permanent magnet, electric motor powers the fuel pump. The electric fuel pump is not a separate, serviceable component.

Fuel Filters

Two fuel filters are used. One is located at the bottom of the fuel pump module. The other is located inside the module. A separate frame mounted fuel filter is not used with any engine.

Both fuel filters are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so.

Fuel Pressure Regulator

The fuel pressure regulator is located within fuel pump module.

Fuel Gauge Sending Unit (Fuel level sensor)

The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card).

3.7LV-6

Scheme 71

1. Remove fuel tank filler tube cap.
2. Perform «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(ref-564649-S02344868012013070500000).
3. Remove negative battery cable at battery.
4. Remove air duct at throttle body air box.
5. Remove air box at throttle body.
6. Remove air resonator mounting bracket at front of throttle body (2 bolts).
7. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection. Refer to «FITTING, QUICK CONNECT»(ref-564649-S03316152772013070500000).
8. Remove necessary vacuum lines at throttle body.
9. Disconnect electrical connectors at all 6 fuel injectors. (Scheme 71) Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.
10. Disconnect electrical connectors at all throttle body sensors.
11. Remove 6 ignition coils. Refer to «COIL-IGNITION»(ref-238310-S20637200592006072400000).
12. Remove four fuel rail mounting bolts (1).
13. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes.
14. Remove fuel rail (with injectors attached) from engine.
15. If fuel injectors are to be removed, Refer to «INJECTOR-FUEL»(ref-212820-S26384904642005122700000).

4.7L V-8

Scheme 72

1. Remove fuel tank filler tube cap.
2. Perform «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(ref-564649-S02344868012013070500000).
3. Remove negative battery cable at battery.
4. Remove air duct at throttle body air box.
5. Remove air box at throttle body.
6. Remove air resonator mounting bracket at front of throttle body (2 bolts).
7. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection. Refer to «FITTING, QUICK CONNECT»(ref-564649-S03316152772013070500000).
8. Remove necessary vacuum lines at throttle body.
9. Disconnect electrical connectors at all 8 fuel injectors. (Scheme 73) Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.
10. Disconnect electrical connectors at all throttle body sensors.
11. Remove 8 ignition coils. Refer to «COIL-IGNITION»(ref-238310-S20637200592006072400000).
12. Remove 4 fuel rail mounting bolts (1).
13. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes.
14. Remove fuel rail (with injectors attached) from engine.
15. If fuel injectors are to be removed, Refer to «INJECTOR-FUEL»(ref-212820-S26384904642005122700000).

5.7L V-8

Scheme 73

Scheme 74

Scheme 75

1. Remove fuel tank filler tube cap.
2. Perform «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(ref-564649-S02344868012013070500000).
3. Remove negative battery cable at battery.
4. Remove flex tube (air cleaner housing to engine).
5. Remove air resonator box at throttle body.
6. Disconnect all spark plug cables from all spark plugs and ignition coils. Do not remove cables from cable routing tray. Note original cable positions while removing.
7. Remove spark plug cable tray from engine by releasing 4 retaining clips (2). Remove tray and cables from engine as an assembly.
8. Disconnect electrical connectors at all 8 ignition coils. Refer to «COIL-IGNITION»(ref-238310-S20637200592006072400000).
9. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection. Refer to «FITTING, QUICK CONNECT»(ref-564649-S03316152772013070500000).
10. Disconnect electrical connectors at all 8 fuel injectors. see scheme 27 Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.
11. Disconnect electrical connectors at all throttle body sensors.
12. Remove four fuel rail mounting bolts (2) and hold-own clamps.
13. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in intake manifold. Gently rock and pull right side of rail until injectors just start to clear intake manifold head holes. Repeat this procedure (left/right) until all injectors have cleared machined holes.
14. Remove fuel rail (with injectors attached) from engine.
15. If fuel injectors are to be removed, Refer to «INJECTOR-FUEL»(ref-212820-S26384904642005122700000).

3.7L V-6

1. If fuel injectors are to be installed, Refer to «INJECTOR-FUEL»(ref-212820-S26384904642005122700000).
2. Clean out fuel injector machined bores in intake manifold.
3. Apply a small amount of engine oil to each fuel injector o-ring. This will help in fuel rail installation.
4. Position fuel rail/fuel injector assembly to machined injector openings in cylinder head.
5. Guide each injector into cylinder head. Be careful not to tear injector o-rings.
6. Push right side of fuel rail down until fuel injectors have bottomed on cylinder head shoulder. Push left fuel rail down until injectors have bottomed on cylinder head shoulder.
7. Install 4 fuel rail mounting bolts and tighten. Refer to «TORQUE - FUEL SYSTEM»(ref-564649-S26967950632013070500000).
8. Install 6 ignition coils. Refer to «COIL-IGNITION»(ref-238310-S20637200592006072400000).
9. Connect electrical connectors to throttle body.
10. Connect electrical connectors at all fuel injectors. see scheme 27 Push connector onto injector (1) and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging on connector.
11. Connect necessary vacuum lines to throttle body.
12. Install air resonator mounting bracket near front of throttle body (2 bolts).
13. Connect fuel line latch clip and fuel line to fuel rail. Refer to «FITTING, QUICK CONNECT»(ref-564649-S03316152772013070500000).
14. Install air box to throttle body.
15. Install air duct to air box.
16. Connect battery cable to battery.
17. Start engine and check for leaks.

1. If fuel injectors are to be installed, Refer to «INJECTOR-FUEL»(ref-212820-S26384904642005122700000).
2. Clean out fuel injector machined bores in intake manifold.
3. Apply a small amount of engine oil to each fuel injector o-ring. This will help in fuel rail installation.
4. Position fuel rail/fuel injector assembly to machined injector openings in cylinder head.
5. Guide each injector into cylinder head. Be careful not to tear injector o-rings.
6. Push right side of fuel rail down until fuel injectors have bottomed on cylinder head shoulder. Push left fuel rail down until injectors have bottomed on cylinder head shoulder.
7. Install 4 fuel rail mounting bolts and tighten. Refer to «TORQUE - FUEL SYSTEM»(ref-564649-S26967950632013070500000).
8. Install 8 ignition coils. Refer to «COIL-IGNITION»(ref-238310-S20637200592006072400000).
9. Connect electrical connectors to throttle body.
10. Connect electrical connectors at air fuel injectors. (Scheme 73) Push connector onto injector (1) and then push and lock red colored slider (2). Verify connector is locked to: injector by lightly tugging on connector.
11. Connect necessary vacuum lines to throttle body.
12. Install air resonator mounting bracket near front of; throttle body (2 bolts).
13. Connect fuel line latch clip and fuel line to fuel rail. Refer to «FITTING, QUICK CONNECT»(ref-564649-S03316152772013070500000).
14. Install air box to throttle body.
15. Install air duct to air box.
16. Connect battery cable to battery.
17. Start engine and check for leaks.

1. If fuel injectors are to be installed, Refer to «INJECTOR-FUEL»(ref-212820-S26384904642005122700000).
2. Clean out fuel injector machined bores in intake manifold.
3. Apply a small amount of engine oil to each fuel injector o-ring. This will help in fuel rail installation.
4. Position fuel rail/fuel injector assembly to machined injector openings in intake manifold.
5. Guide each injector into intake manifold. Be careful not to tear injector o-rings.
6. Push right side of fuel rail down until fuel injectors have bottomed on shoulders. Push left fuel rail down until injectors have bottomed on shoulders.
7. Install 4 fuel rail holdown clamps and 4 mounting bolts. Refer to «TORQUE - FUEL SYSTEM»(ref-564649-S26967950632013070500000).
8. Position spark plug cable tray and cable assembly to intake manifold. Snap 4 cable tray retaining clips into intake manifold.
9. Install all cables to spark plugs and ignition coils.
10. Connect electrical connector to throttle body.
11. Install electrical connectors to all 8 ignition coils. Refer to «COIL-IGNITION»(ref-238310-S20637200592006072400000).
12. Connect electrical connector to throttle body.
13. Connect electrical connectors at all fuel injectors. (Scheme 73) Push connector onto injector (1) and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging on connector.
14. Connect fuel line latch clip and fuel line to fuel rail. Refer to «FITTING, QUICK CONNECT»(ref-564649-S03316152772013070500000).
15. Install air resonator to throttle body (2 bolts).
16. Install flexible air duct to air box.
17. Connect battery cable to battery.
18. Start engine and check for leaks.