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TSB 14-02-89

Insufficient Fuel Volume Due To A Ruptured Fuel Pump Supply Hose

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Models: 1988-89 D/AD Ram Pickup, Ramcharger

Also Body Code:
B/AB - DODGE RAM VAN/WAGON (RWD)
D/AD - DODGE RAM PICKUP/RAMCHARGER SPORT UTILITY (RWD, 4WD)
N/AN - DODGE DAYOTA/DAKOTA SPORT (RWD, 4WD)

Symptom/Condition:

No start, surge or hesitation due to insufficient fuel supply to the throttle body. This condition may be caused by a ruptured fuel supply hose at the in-tank fuel pump module.

Diagnosis:

Before performing the diagnosis for the above SYMPTOM/ CONDITION, perform the Fuel System Pressure Release Procedure as called out in the "Fuel System" section of the appropriate 1988 or 1989 service manual.

The following procedure will help in diagnosing a ruptured fuel pump supply hose.

1. Disconnect the fuel supply hose from the throttle body.

2. Connect fuel system pressure tester, Miller Tool C-4799-A, to the fuel supply hose.

3. Connect DRB 11 diagnostic tester to the vehicle connector. Turn the ignition key to the "Run" position. Cycle the DRB II to the Actuate Outputs Test for "Auto Shutdown Relay." This will activate the fuel pump and pressurize the system.

4. The pressure gauge should stabilize at 100 Kpa ± 7 Kpa (14.5 psi ± 1 psi).

5. Clamp the fuel return hose shut at the throttle body. The fuel pressure will increase and stabilize at approximately 345 Kpa (50 psi).

6. Turn the ignition to the "OFF" position.

7. If the fuel pressure drops slightly (less than 5 psi) and then stabilizes, the system is operating correctly.

8. If the fuel pressure drops rapidly (to below 10 psi in one minute or less) a leak is present in the fuel supply system.

9. if no leaks are visible between the fuel tank and the throttle body, the problem is most likely a ruptured fuel supply hose at the fuel pump module.

10. Remove the fuel return hose clamp and the fuel pressure tester.

Parts Required:

1 Fuel Supply Hose (B/AB)                PN 52006220
1 Fuel Supply Hose (D/AD, N/AN)    PN 52006219

Service Procedure:

This procedure outlines the replacement of the fuel supply hose at the fuel pump module.

1. Remove fuel tank assembly from vehicle.

2. Remove fuel pump module from fuel tank.

3. Using service manual procedures (Page 14-4 of 19B9 Rear-wheel-Drive Truck Manual #81-370-9008), disassemble fuel pump module assembly just to the point of being able to remove the fuel supply hose from the fuel pump module lid (Figure 1).

4. Remove fuel supply hose from fuel pump.

5. Remove pump mounting bracket and rubber collar from hose. Discard hose and clamps.

6. Slide clamps included in package onto new supply hose (see "PARTS REQUIRED" for application). Install supply hose with the short end attached to module lid. Attach fuel pump to supply hose. Tighten clamps to 1 N-m (10 in. lbs.).

7. Install pump mounting bracket and rubber collar on hose, positioning bracket just under locating clamp on hose.

8. Reassemble module.

9. Install module into fuel tank and install fuel tank in vehicle.

10. Start vehicle to check for fuel leaks and to verify proper operation.

Notes:

POLICY:     Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No.       14-50-01-94 (B) . . . . . . . . . . . . . . . .  1.4 Hrs.
                                                            (A, D), X, W, N) . . . . . . 1.3 Hrs.

FAILURE CODE: X2 - Split, Cut or Torn