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Home >> Dodge and Ram >> 1999 >> Durango 5.9 Z, 4WD, Part Time >> Repair and Diagnosis >> Engine Performance >> Remove, Overhaul & Install >> Engine Controls - Component Remove/Install/Overhaul - RWD - Gasoline >> Fuel System >> Fuel System Pressure Release
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Fuel System Pressure Release

WARNING: Always release fuel pressure before disconnecting any fuel injection-related component. DO NOT allow fuel to contact engine or electrical components.
  1. Remove fuel cap from fuel tank. Note location of spring loaded flapper valve inside fuel tank filler tube assembly. Flapper valve is located just below the fuel cap area on fuel tank filler tube assembly. Flapper valve is used as a secondary way of sealing the fuel tank if fuel cap was not properly tightened.
    WARNING: When opening flapper valve inside fuel tank filler tube assembly, ensure a non-metallic object is used to prevent any sparks.
  2. Using a non-metallic object, push flapper valve inside filler tube assembly downward to release any pressure from the fuel tank. Ensure all pressure is released from fuel tank.
  3. Remove fuel pump relay from Power Distribution Center (PDC). Fuel pump relay may be identified by label on inside of PDC cover. See POWER DISTRIBUTION CENTER (PDC) LOCATION  table.
  4. On all models, start engine and allow engine to idle until engine stalls. Attempt to restart engine until engine will no longer run. Turn ignition off.
    CAUTION: Ensure steps 1)  through 4)  are performed before proceeding. Steps 3)  and 4)  must be performed to ensure most of the fuel pressure is released from fuel rails to prevent an excessive amount of fuel being delivered into the cylinders.
  5. Remaining fuel pressure is released by energizing a fuel injector. Disconnect electrical connector at any fuel injector.
  6. Connect jumper wire between one electrical terminal on fuel injector and positive battery terminal. Connect another jumper wire on remaining electrical terminal on fuel injector.
    CAUTION: DO NOT apply battery voltage to fuel injector for extended periods, or fuel injector may be damaged.
  7. Momentarily touch remaining end of jumper wire to negative battery terminal in short intervals to energize fuel injector and release remaining fuel pressure.
  8. Remove jumper wires. Reinstall electrical connector and fuel pump relay. Fuel system components may now be serviced. Cover fuel lines with shop towel before disconnecting, as some residual fuel pressure may exist.
  9. Diagnostic Trouble Code (DTCs) may have been stored in Powertrain Control Module (PCM) due to the removal of fuel pump relay. Using scan tool, clear DTCs from PCM. See appropriate SELF-DIAGNOSTICS article for clearing of DTCs.
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