LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Dodge and Ram >> 2003 >> Durango R/T, 5.9 Z >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - System & Component Testing >> Fuel Systems >> Fuel Delivery
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Fuel Delivery

NOTE: For circuit identification and wiring diagram, see WIRING DIAGRAMS  . After each repair procedure has been completed, reconnect all components. Perform the following VERIFICATION TEST to ensure system is functioning properly:
  1. Turn the ignition on, with the engine off. Using DRBIII(R) scan tool, actuate the ASD FUEL SYSTEM TEST. Listen for fuel pump operation at fuel tank. If the fuel pump operates, stop all actuation tests and go to next step. If fuel pump does not operate, stop all actuation tests and go to step  6 .
    2. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released.
  2. Turn the ignition off. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE  . Install a fuel pressure gauge to the fuel rail test port. Turn the ignition on, with the engine off. With the DRBIII(R) scan tool, actuate the ASD FUEL SYSTEM TEST and observe the fuel pressure gauge. Fuel pressure specification should be 44.2-54.2 psi (305-373 kPa). Choose a conclusion that best matches your fuel pressure reading. If fuel pressure is below specification, stop all actuations and go to next step. If fuel pressure is within specification, stop all actuations and go to step  5 . If fuel pressure is above specification, stop all actuations and replace fuel filter/fuel pressure regulator.
  3. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE  . Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. Connect Fuel Line Adapter (6539) for 5/16" fuel line or (6631) for 3/8" fuel line between disconnected fuel pressure line and fuel pump module. Attach a fuel pressure test gauge to the "T" fitting of the adapter. Turn the ignition on, with the engine off. With the DRBIII(R) scan tool, actuate the ASD FUEL SYSTEM TEST and observe the fuel pressure gauge. Turn the ignition off. Stop all actuations. Fuel pressure specification is 44.2-54.2 psi (305-373 kPa). If the fuel pressure is not within specification, go to next step. If fuel pressure is within specification, repair or replace fuel supply line as necessary.
  4. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE  . Remove the fuel pump module from the fuel tank and inspect the fuel pump inlet strainer. See Fig 1 and Fig 2 . If the fuel pump inlet strainer is plugged, replace the fuel pump inlet strainer. If the fuel pump inlet strainer is not plugged, replace fuel pump module.
    5. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released.
    CAUTION: DO NOT operate the fuel pump for more than 7 seconds in this step. Fuel pump module reservoir may run empty and damage to the fuel pump will result.
    NOTE: A good fuel pump will deliver at least 0.5 pt. (0.25L) of fuel in 7 seconds.
  5. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE  . Disconnect the fuel supply line at the fuel rail. See Fig 3 . Connect Fuel Line Adapter (6539) for 5/16" fuel line or (6631) for 3/8" fuel line to the disconnected fuel supply line. Insert the other end of the adapter into a graduated container. Turn the ignition on. With the DRBIII(R) scan tool, actuate the ASD FUEL SYSTEM TEST for 7 seconds. Stop the ASD FUEL SYSTEM TEST. If the fuel pump volume is at least 0.5 pt. (0.25L), test is complete. If the fuel pump volume is not at least 0.5 pt. (0.25L), check for a kinked/damaged fuel supply line between the fuel tank and fuel rail. If okay, replace the fuel pump module.
  6. Turn the ignition off. Disconnect fuel pump module harness connector. See Fig 4 . Turn the ignition on, with the engine off. With the DRBIII(R) scan tool, actuate the ASD FUEL SYSTEM TEST. Using a 12-volt test light connected to ground, probe the fuel pump relay output circuit at the fuel pump module harness connector. If the test light illuminates brightly, go to next step. If test light does not illuminate brightly, go to step  9 .
  7. Turn the ignition off. Using test light connected to 12-volts, backprobe the fuel pump ground circuit at the fuel pump module harness connector. If the test light illuminates brightly, go to next step. If test light does not illuminate brightly, repair the fuel pump ground circuit for an open or high resistance.
  8. There are no possible causes remaining, replace fuel pump module.
  9. Turn the ignition off. Remove the fuel pump relay from the PDC. See Figure . Using 12-volt test light connected to ground, backprobe the fuel pump relay fused B+ circuit at the PDC. See Figure . If the test light illuminates brightly, go to next step. If the test light does not illuminate brightly, repair the fuel pump relay fused B+ circuit for an open. Inspect the related fuse and replace if necessary.
  10. Measure the resistance of the fuel pump relay output circuit from the relay connector to the fuel pump module connector. Is the resistance is less than 5.0 ohms, replace the fuel pump relay. If resistance is 5 ohms or more, repair the fuel pump relay output circuit for an open.
Fig 1: Locating Fuel Pump Module
G00088606Courtesy of DAIMLERCHRYSLER
Fig 2: Identifying Fuel Pump Module Components (Typical)
G00104115Courtesy of CHRYSLER CORP.
Fig 3: Locating Fuel Injectors (4.7L Is Shown)
G00094358Courtesy of DAIMLERCHRYSLER CORPORATION
Fig 4: Identifying Fuel Pump Module Harness Connector Terminals
G00235033Courtesy of CHRYSLER CORP.
scientia non olet · About LEMON Manuals