Engine Controls - Remove/install/overhaul - Diesel: Removal & Installation Dodge Cab & Chassis Dakota

TURBOCHARGER ASSEMBLY REMOVAL

1. Disconnect negative battery cable. Remove air intake piping and exhaust pipe at turbocharger. On intercooled models, remove intercooler inlet duct from turbocharger. (Scheme 17) On non-intercooled models, remove air crossover tube between turbocharger and intake manifold.
2. Remove and plug turbocharger oil lines. Remove turbocharger retaining nuts and turbocharger. Plug all air intake and oil line openings.

Note. Compressor and turbine assembly is a balanced unit. If, during disassembly, compressor or turbine wheel are damaged, turbine shaft and wheel, and compressor wheel MUST be replaced as an assembly.

TURBOCHARGER INSTALLATION

To install, reverse removal procedure using new gaskets. Coat all bolts and studs with anti-seize compound. Install oil drain tube on turbocharger. Pour 3 oz. (60 cc) of clean oil in oil inlet while spinning turbocharger. Install remaining components and tighten fasteners to specification. See TORQUE SPECIFICATIONS table at end of article.

INTERCOOLER REMOVAL

1. Remove grille. Remove front support bracket, located above center of intercooler. On A/C-equipped models, discharge A/C system.
2. Remove bolt from center of sealing plate on A/C lines at the condenser. Remove condenser-to-intercooler retaining nuts. Lift condenser and sealing plate from intercooler. Plug all A/C lines to prevent contamination.
3. Remove intercooler inlet and outlet ducts. (Scheme 17) Remove intercooler retaining bolts. Pivot intercooler forward and upward to remove.

INTERCOOLER INSTALLATION

To install, reverse removal procedure. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS table at end of article. Evacuate and recharge A/C system (if equipped).

Scheme 17

HIGH-PRESSURE FUEL LINE REMOVAL

1. Disconnect negative battery cable. Disconnect control linkage and remove control linkage bracket from fuel injection pump (if necessary). Mark high-pressure fuel line location for reassembly reference.
2. Disconnect high-pressure fuel lines at fuel injectors and fuel injection pump. Remove high-pressure fuel line clamp retaining bolts. Remove high-pressure fuel lines.

HIGH-PRESSURE FUEL LINE INSTALLATION

To install, reverse removal procedure. Bleed high-pressure fuel lines. See FUEL LINE BLEEDING under FUEL SYSTEM.

FUEL INJECTION PUMP REMOVAL

1. Disconnect negative battery cable. Disconnect necessary electrical connections at fuel injection pump. Disconnect control linkages from control lever on fuel injection pump. DO NOT remove control lever from fuel injection pump.
2. Disconnect control linkage bracket. Remove and cap high-pressure fuel lines. Use wrench to hold delivery valves on fuel injection pump, while removing high-pressure lines. Mark fuel line location for reassembly reference.
3. Disconnect air fuel control tube. This is the tube from fuel injection pump to cylinder head. Disconnect drain tube from fuel injection pump. Disconnect fuel supply line from fuel injection pump.
4. On intercooled models, remove bolt from rear support bracket on fuel injection pump. Remove rear support bracket-to-cylinder block bolts. Loosen center bolt on rear support bracket. Pivot rear support bracket toward rear of engine.
5. On non-intercooled models, remove retaining bolts and rear support bracket on fuel injection pump. On all models, remove oil fill tube from front timing gear cover. Place shop towel in front of fuel pump drive gear to prevent retaining nut and washer from falling during removal. Remove fuel pump drive gear retaining nut and washer. CAUTION: DO NOT allow fuel pump drive gear retaining nut or washer to fall into front timing gear cover.
6. Rotate engine clockwise so No. 1 cylinder is at TDC of compression stroke. Engine can be rotated by removing dust cover from transmission adapter plate and installing Engine Barring Tool (3377462) in transmission adapter plate. (Scheme 18)
7. When No. 1 cylinder is at TDC, key of fuel injection pump shaft should be pointing toward bottom of engine. Ensure timing pin will engage. (Scheme 18) Timing pin is located below fuel injection pump. CAUTION: Carefully engage timing pin to avoid breaking tip of timing pin. DO NOT rotate engine with timing pin engaged.
8. Note if timing marks on fuel injection pump flange and gear housing are aligned for reassembly reference, if original fuel injection pump is installed. (Scheme 19) These timing marks apply to each engine and fuel injection pump. Timing marks cannot be used to exchange fuel injection pumps.
9. Loosen lock bolt on fuel injection pump and remove special washer. (Scheme 19) Tighten lock bolt to 22 ft. lbs. (30 N.m). This will lock fuel injection pump shaft from rotating. Retain special washer for reassembly.
10. Using gear puller and two 8 mm X 1.25" bolts, pull fuel pump drive gear free from fuel injection pump shaft. Remove retaining nuts, fuel injection pump and gasket.

Scheme 18

Scheme 19

FUEL INJECTION PUMP INSTALLATION (ORIGINAL)

1. Ensure gasket surfaces are clean. Ensure No. 1 cylinder is at TDC and timing pin is engaged. Install new gasket on cylinder block. Install key in fuel injection pump shaft and install fuel injection pump. DO NOT allow key to drop from fuel injection pump shaft. CAUTION: DO NOT allow key to fall from fuel injection pump shaft during installation.
2. Install mounting nuts. DO NOT tighten nuts at this time. Fuel injection pump must be free to rotate in slots. Install fuel pump drive gear retaining nut and washer. Tighten retaining nut to 11-15 ft. lbs. (15-20 N.m).
3. If fuel injection pump timing marks on fuel injection flange and gear housing were aligned at removal, fuel injection pump timing does not require adjustment. If marks were not aligned, check fuel injection pump timing. See FUEL INJECTION PUMP TIMING in D - DIESEL ADJUSTMENTS article in the ENGINE PERFORMANCE Section.
4. If timing marks were aligned at removal, rotate fuel injection pump to align timing marks. Tighten mounting nuts to 18 ft. lbs. (24 N.m). Loosen lock bolt and install special washer under lock bolt. Tighten lock bolt to 10 ft. lbs. (14 N.m). Tighten fuel pump drive gear nut to specification. See «TORQUE SPECIFICATIONS»(ref-10657-S21705618302000111300000) table at end of article.
5. Disengage timing pin if not previously disengaged. To install remaining components, reverse removal procedure. Loosely install all bolts in rear support bracket.
6. On intercooled models, tighten rear support bracket bolts to vacuum pump, cylinder block and then to fuel injection pump. On non-intercooled models, tighten rear support bracket bolts to cylinder block and then to fuel injection pump. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-10657-S21705618302000111300000) table at end of article.
7. Install and bleed fuel lines. See «FUEL LINE BLEEDING»(ref-10657-S01374795242000111300000) under FUEL SYSTEM. Ensure cable rod is adjusted so control lever contacts low-speed screw when in idle position. Cable rod is located between control linkage and control lever on fuel injection pump.
8. Ensure control lever on fuel injection pump moves over center position and rests against breakover spring (located in center of control lever) when in full throttle position.

FUEL INJECTION PUMP INSTALLATION (NEW OR REBUILT)

1. Ensure gasket surfaces are clean. Ensure No. 1 cylinder is at TDC and timing pin is engaged. Install new gasket on cylinder block. Install key in fuel injection pump shaft and install fuel injection pump. CAUTION: DO NOT allow key to fall from fuel injection pump shaft during installation.
2. Install mounting nuts. DO NOT tighten nuts at this time. Fuel injection pump must be free to rotate in slots. Install fuel pump drive gear retaining nut and washer. Tighten nut to 11-15 ft. lbs. (15-20 N.m).
3. Rotate fuel injection pump toward cylinder head to take up gear lash. Check fuel injection pump timing. See FUEL INJECTION PUMP TIMING in D - DIESEL ADJUSTMENTS article in the ENGINE PERFORMANCE Section. CAUTION: Ensure lock bolt is loosened and special washer is installed under lock bolt. Lock bolt must be tightened to 10 ft. lbs. (14 N.m).
4. Once correct timing is obtained and mounting nuts are tightened, place timing mark on fuel injection pump flange to align with mark on gear housing. (Scheme 19)
5. Disengage timing pin if not previously disengaged. To install remaining components, reverse removal procedure. Install all bolts in rear support.
6. On intercooled models, tighten rear support bracket bolts to vacuum pump, cylinder block and then to fuel injection pump. On non-intercooled models, tighten rear support bracket bolts to cylinder block and then to fuel injection pump. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-10657-S21705618302000111300000) table at end of article.
7. Install and bleed fuel lines. See «FUEL LINE BLEEDING»(ref-10657-S01374795242000111300000) under FUEL SYSTEM. Ensure ensure cable rod is adjusted so control lever contacts low-speed screw when in idle position. Cable rod is located between control linkage and control lever on fuel injection pump.
8. Ensure control lever on fuel injection pump moves over center position and rests against breakover spring (located in center of control lever) when in full throttle position.

FUEL LIFT PUMP REMOVAL & INSTALLATION

1. Disconnect negative battery cable. Disconnect fuel lines at fuel lift pump. Remove retaining bolts, fuel lift pump and gasket.
2. To install, reverse removal procedure using new pump mounting gasket and fuel line banjo bolt sealing washers. Bleed low-pressure fuel lines. See «FUEL LINE BLEEDING»(ref-10657-S01374795242000111300000) under FUEL SYSTEM.

FUEL HEATER REMOVAL

1. Fuel heater is located between fuel/water separator filter and filter adapter on cylinder head. Ensure area is clean around fuel heater.
2. Disconnect water-in-fuel sensor electrical connection at bottom of fuel/water separator filter. Remove fuel/water separator filter. Disconnect electrical connection at fuel heater. Remove retaining adapter from center of fuel heater. Remove fuel heater and seal rings.

FUEL HEATER INSTALLATION

1. To install, reverse removal procedure using new seal rings. Tighten retaining adapter to specification. See «TORQUE SPECIFICATIONS»(ref-10657-S21705618302000111300000) table at end of article.
2. If water-in-fuel sensor is removed from fuel/water separator, coat water-in-fuel sensor sealing surface with engine oil before installing on fuel/water separator filter.
3. Ensure fuel/water separator filter is full of diesel fuel and sealing surface is coated with engine oil before installing. Tighten fuel/water separator filter 1/2 turn after it contacts fuel heater.

FUEL INJECTOR REMOVAL

1. Disconnect negative battery cable. Remove throttle linkage and bracket. Remove high-pressure fuel lines and mark location for reassembly reference. Remove fuel drain lines from fuel injectors, and plug all fuel openings.
2. Clean around fuel injector. Hold fuel injector body with wrench while loosening hold-down nut. Using Fuel Injector Puller (3823276), pull fuel injectors from cylinder head. Remove sealing ring (located below fuel injector) from cylinder head.

FUEL INJECTOR INSTALLATION

1. Install new sealing ring on fuel injector. Coat fuel injector retaining nut and top of fuel injector body with anti-seize compound. Install fuel injector in original position.
2. Ensure protrusion side of fuel injector aligns with notch area of cylinder head. Tighten fuel injector retaining nut to specification. See «TORQUE SPECIFICATIONS»(ref-10657-S21705618302000111300000) table at end of article. Once fuel injector retaining nut is tightened, push "O" ring on top of fuel injector into groove. CAUTION: Ensure protruding side of fuel injector aligns with notch area of cylinder head.
3. To install remaining components, reverse removal procedure using new sealing washers. Install and bleed high-pressure fuel lines. See «FUEL LINE BLEEDING»(ref-10657-S01374795242000111300000) under FUEL SYSTEM.

INTAKE MANIFOLD HEATER REMOVAL & INSTALLATION (INTERCOOLED)

1. Disconnect negative battery cable. Intake manifold heater is located between air inlet housing and intake manifold cover. Disconnect intercooler outlet duct from air inlet housing. (Scheme 17)
2. Remove high-pressure fuel lines (if necessary). Hold delivery valves on fuel injection pump with wrench while removing high-pressure lines. Mark fuel line location for reassembly reference.
3. Disconnect intake manifold heater electrical connector. Disconnect fuel heater ground wire (located above fuel filter) from intake manifold cover. Remove retaining bolts, air inlet housing and gasket. Remove intake manifold heater and gasket.
4. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-10657-S21705618302000111300000) table at end of article. Install and bleed high-pressure fuel lines (if removed). See «FUEL LINE BLEEDING»(ref-10657-S01374795242000111300000) under FUEL SYSTEM.

1. Disconnect negative battery cable. Disconnect control linkage at fuel injection pump.
2. Disconnect electrical connections at intake manifold heater. Intake manifold heater is located below air crossover tube from turbocharger and intake manifold.
3. Loosen air crossover tube clamps at turbocharger. Remove retaining bolts and air crossover tube from intake manifold. Remove intake manifold heater and gaskets.
4. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-10657-S21705618302000111300000) table at end of article.

INTAKE MANIFOLD HEATER RELAYS REMOVAL & INSTALLATION

Disconnect negative battery cable. Disconnect electrical connections for intake manifold heater relays, located on inner fenderwell. (Scheme 20) Remove retaining bolts and intake manifold heater relays. To install, reverse removal procedure.

Scheme 20

SHUTOFF SOLENOID VALVE REMOVAL & INSTALLATION

1. Disconnect wire from shutoff solenoid valve, located on rear of fuel injection pump. Ensure area around shutoff solenoid valve is clean. Remove shutoff solenoid valve, plunger and spring. CAUTION: DO NOT allow plunger and spring to fall in fuel injection pump while servicing shutoff solenoid valve.
2. To install, reverse removal procedure using new "O" ring. Tighten shutoff solenoid valve to specification. See «TORQUE SPECIFICATIONS»(ref-10657-S21705618302000111300000) table at end of article.

THERMISTOR REMOVAL & INSTALLATION (NON-INTERCOOLED MODELS)

Thermistor is located in air intake above fuel/water separator filter. Disconnect electrical connection and remove thermistor. To install, reverse removal procedure. Tighten thermistor to specification. See TORQUE SPECIFICATIONS table at end of article.

THROTTLE POSITION SENSOR (TPS) REMOVAL (INTERCOOLED)

TPS is located above control lever on fuel injection pump. (Scheme 21) Disconnect electrical connector at TPS. Remove TPS retaining screws. Lift TPS straight upward from fuel injection pump.

THROTTLE POSITION SENSOR (TPS) INSTALLATION (INTERCOOLED)

1. Install TPS in bracket on fuel injection pump. Ensure adapter on TPS aligns with opening in fuel injection pump shaft. (Scheme 21)
2. If adapter does not align with fuel injection pump shaft, remove TPS bracket retaining screws. Place adapter on fuel injection pump shaft so TPS bracket must be rotated clockwise to align retaining screw holes.
3. Ensure adapter is even or slightly above top of fuel injection pump shaft. To adjust adapter position, hold nylon shaft in place and rotate adapter.
4. Tighten bracket retaining screws. Adjust TPS. See THROTTLE POSITION SENSOR (TPS) in D - DIESEL ADJUSTMENTS article in ENGINE PERFORMANCE Section.

Scheme 21

WATER-IN-FUEL SENSOR REMOVAL & INSTALLATION

1. Disconnect water-in-fuel sensor electrical connection at bottom of fuel/water separator filter. Remove fuel/water separator filter and drain fuel. Unscrew water-in-fuel sensor from bottom of fuel/water separator filter.
2. To install, reverse removal procedure using new "O" rings. Lubricate "O" rings and fuel/water separator filter sealing surface with engine oil before installing. Only hand tighten water-in-fuel sensor. Fill fuel/water separator filter with diesel fuel and install. Tighten fuel/water separator filter 1/2 turn after it contacts sealing surface of fuel heater.

FUEL/WATER SEPARATOR FILTER REMOVAL

1. Disconnect water-in-fuel sensor electrical connection at bottom of fuel/water separator filter. Remove fuel/water separator filter. Ensure electrical connection on fuel heater (located above filter) is not rotated against cylinder block when removing fuel/water separator filter.
2. Remove square cut "O" ring from fuel/water separator filter-to-fuel heater contact area. Drain fuel/water separator filter. Unscrew water-in-fuel sensor from bottom of filter.

FUEL/WATER SEPARATOR FILTER INSTALLATION

1. To install, reverse removal procedure using new "O" rings. Lubricate "O" rings and fuel/water separator filter sealing surface with engine oil before installing.
2. Reinstall water-in-fuel sensor in bottom of fuel/water separator filter. Hand tighten water-in-fuel sensor ONLY. Fill fuel/water separator filter with diesel fuel before installing.
3. Tighten fuel/water separator filter 1/2 turn after it contacts sealing surface of fuel heater.