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

Removal

1. Disconnect distributor lead wire at wiring harness connector. Loosen distributor cap retaining screws. (Scheme 1) Lift off distributor cap.
2. Rotate engine crankshaft until distributor rotor is pointing toward intake plenum. Scribe a mark on plenum at this point to indicate rotor position as reference when reinstalling distributor.
3. Remove distributor hold-down nut. Carefully lift distributor from engine.

Installation

1. Position distributor in engine. Ensure "O" ring is properly seated on distributor. Replace "O" ring if it is cracked or nicked.
2. Carefully engage distributor drive with camshaft drive so, when distributor is installed properly, rotor aligns with reference mark on intake plenum.
3. Install distributor cap. Check all high tension wires for good connections. Install and finger tighten hold-down nut. Connect distributor lead wire at wiring harness connector. Set ignition timing.

Scheme 1

Removal & Installation

1. Disconnect distributor pick-up lead wire at wiring harness connectors. Remove splash shield retaining screws and remove splash shield (if equipped).
2. Loosen distributor cap retaining screws or unfasten distributor cap retaining clips. Remove distributor cap. Scribe a mark on edge of distributor housing to indicate position of rotor as reinstallation reference when.
3. Remove ignition rotor from distributor shaft. On 3.9L, 5.2L and 5.9L, remove Hall Effect pick-up attaching screws on opposite sides of distributor housing. (Scheme 2)
4. Carefully lift Hall Effect pick-up assembly from distributor housing. To install, reverse removal procedure.

Scheme 2

Remove spark plug cables from coil. (Scheme 3) Remove electrical connector. Remove ignition coil fasteners. To install, reverse removal procedure and tighten fasteners to 105 INCH lbs. (12 N.m).

Scheme 3

1. Disconnect camshaft angle sensor lead at wiring harness connector. Loosen sensor retaining bolt far enough to allow slot in sensor to slide past bolt.
2. Pull sensor up out of chain case cover. DO NOT pull on sensor lead. Removal effort will be high due to "O" ring seal on sensor. A light tap to top of sensor prior to removal may reduce removal effort.

1. If reinstalling removed sensor, clean off old spacer on sensor face. A new spacer must be attached to face before installation. Inspect "O" ring for damage and replace if necessary.
2. If replacing sensor, confirm paper spacer is attached to sensor face and "O" ring is positioned in groove of new sensor. Apply a couple drops of clean engine oil to "O" ring prior to installation.
3. Install sensor in chain case cover. Push sensor down until it contacts cam timing gear. Hold sensor in this position and tighten retaining bolt to 105 INCH lbs. (12 N.m).
4. Connect sensor lead wire at wiring harness connector. Position lead wire away from accessory belt.

1. Disconnect crankshaft angle sensor pick-up lead at wiring harness connector. (Scheme 4) Remove sensor retaining bolt. Pull sensor straight up out of transaxle housing.
2. If reinstalling removed sensor, clean off old spacer on sensor face. A new spacer MUST be attached to sensor face before installation. If replacing sensor, paper spacer is attached to face of new sensor.

Install sensor in transaxle and push sensor down until it contacts drive plate. Hold in this position and install retaining bolt. While still holding sensor down, tighten bolt to 105 INCH lbs. (12 N.m). Connect sensor lead wire to wiring harness connector.

Scheme 4

Remove fuel tank. See FUEL TANK REMOVAL under FUEL TANK. Using a hammer and a brass drift punch, carefully tap lock ring counterclockwise to release pump. Remove fuel pump from tank. (Scheme 5)

Wipe seal area of tank clean. Install a new "O" ring seal in position on pump. Position fuel pump in tank so fuel return hose is not kinked. Install lock ring. Using a hammer and brass drift punch, drive ring around clockwise to lock pump in place. DO NOT overtighten pump lock ring as it may leak. Install fuel tank. See INSTALLATION under FUEL TANK.

Scheme 5

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove fuel tank. See REMOVAL under FUEL TANK. Unclip fuel vapor hose and fuel drain hose from fuel tank. Remove fuel pump module retaining clamp. (Scheme 6) Remove fuel pump module.

Wipe seal area of tank clean and place new seal in position on pump. Position fuel pump module so arrow on edge of module is between 2 lines on fuel tank. Compress fuel pump module and install retaining clamp. Tighten clamp to 40 INCH lbs. (4.5 N.m). Install fuel tank. See INSTALLATION under FUEL TANK.

Scheme 6

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove fuel tank. See REMOVAL under FUEL TANK. Remove fuel pump module lock nut. Lock nut is threaded onto fuel tank. (Scheme 7) Fuel pump module will spring up from its position when lock nut is removed. Remove module from tank.

Install fuel pump module into fuel tank. Push module down and install lock nut. Install fuel tank. See INSTALLATION under FUEL TANK.

Scheme 7

1. Disconnect negative battery cable. Remove fuel tank filler cap to release any tank pressure. Drain fuel tank into a suitable holding tank. See DRAINING FUEL TANK. Position vehicle on hoist. Remove screws that hold filler tube to inner and outer quarter panel.
2. Raise vehicle on hoist. Disconnect all wiring and lines from tank. Use a transmission jack to support fuel tank and remove bolts from fuel tank straps. Lower tank slightly and carefully work filler tube from tank. Lower fuel tank. Disconnect vapor separator rollover valve hose and remove fuel tank from vehicle.

1. Place fuel tank on top of transmission jack. Connect vapor separator rollover valve hose. Raise tank into position and carefully work filler tube into tank. Transmission fluid may be used to lubricate tube as an aid in assembly. CAUTION: Ensure vapor vent hose is clipped to tank and is not pinched between tank and floor pan during installation. Ensure straps are not twisted or bent before or after tightening strap nuts.

2). Install strap bolts and tighten to 40 ft. lbs. (54 N.m). Remove transmission jack. Connect lines, drain tube cap and wiring connector. Use new hose clamps and tighten to 10 INCH lbs. (1 N.m).

3) Install filler tube and tighten filler tube-to-inner and outer quarter panel screws to 17 INCH lbs. (1.9 N.m). On affected models, be sure to install gasket between filler tube and inner quarter panel before installing mounting screws.

4) Replace cap on drain tube using new hose clamp. Fill fuel tank and replace filler cap. Connect negative battery cable. Check for proper operation.

1. Disconnect negative battery cable. Remove fuel tank filler cap to release fuel tank pressure. Drain fuel tank into a suitable holding tank. See DRAINING FUEL TANK. Raise vehicle on hoist. Disconnect all vent hoses and filler hose.
2. Place a transmission jack under center of fuel tank and apply slight pressure. Remove fuel tank retaining straps. Lower tank on transmission jack far enough to access fuel pump module connectors.
3. Disconnect fuel tubes and fuel gauge sending unit connections from fuel pump module. Remove ground strap (if equipped). Remove fuel tank.

1. Place fuel tank on top of transmission jack and raise high enough to connect fuel tubes and fuel gauge wire to fuel pump module. Connect fuel tubes and fuel gauge wire to fuel pump module.
2. Raise tank into position. Install ground strap (if equipped). Install fuel tank mounting straps. On Ramcharger, connect and tighten nuts to end of threads on "J" bolts. On all other models, tighten straps to 35 ft. lbs. (47 N.m). Remove transmission jack.
3. Connect vent hoses, filler tube and drain tube cap. Install new hose clamps and tighten securely. Connect fuel line if disconnected earlier. Refill tank and inspect all hoses and lines for leaks. Reconnect negative battery cable. Pressurize system and check for leaks.

1. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable.
2. Remove air cleaner-to-throttle body hose. Remove throttle cable and transaxle kickdown linkage (if equipped). Remove wiring connectors for automatic idle speed motor and throttle position sensor from throttle body.
3. Remove vacuum/vapor harness from throttle body. Remove brake booster hose from air intake plenum. Remove ignition coil from air intake plenum. Disconnect coolant temperature sensor.
4. Remove vacuum connections from air intake plenum vacuum connector. Remove fuel hoses from fuel rail. Remove fasteners attaching air intake plenum to intake manifold. Remove air intake plenum.
5. Cover intake manifold with suitable cover when servicing. Remove vacuum hoses from fuel rail. Disconnect fuel injector wiring harness from engine wiring harness.
6. Remove fuel pressure regulator attaching bolts. Remove regulator from rail. Remove fuel rail attaching bolts and lift fuel rail assembly from intake manifold.

1. Ensure injectors are seated into receiver cups on rail with lock rings in place. See REMOVAL under FUEL INJECTORS. Ensure injector holes are clean and all plugs have been removed.
2. Lubricate injector "O" rings with a drop of clean engine oil to ease installation. Push the tip of each injector into its port. Push entire assembly into place until injectors are seated in ports.
3. Install 3 fuel rail attaching bolts and tighten to 115 INCH lbs. (13 N.m). Lubricate fuel pressure regulator "O" ring with a drop of clean engine oil. Install fuel pressure regulator onto fuel rail.
4. Install fuel pressure regulator attaching bolts and tighten to 77 INCH lbs. (8.7 N.m). Install fuel supply and return tube hold-down bolt. Install vacuum crossover tube hold-down bolt. Tighten both bolts to 95 INCH lbs. (10 N.m).
5. Tighten fuel pressure regulator hose clamps to 10 INCH lbs. (1 N.m). Connect fuel injector wiring harness to engine wiring harness. Connect vacuum harness to fuel rail assembly. Remove covering from lower intake manifold. Clean manifold surface.
6. Place intake manifold gaskets with beaded sealer up on lower manifold. Place air intake plenum in position. Loosely install ignition coil to intake manifold. Install manifold attaching fasteners.
7. Tighten the 8 manifold fasteners to 115 INCH lbs. (13 N.m). Tighten the 2 ignition coil fasteners to 96 INCH lbs. (10 N.m). Connect fuel line to fuel rail. Tighten hose clamps to 10 INCH lbs. (1 N.m).
8. Connect vacuum harness to air intake plenum and fuel pressure regulator. Reconnect coolant temperature sensor electrical connector. Connect brake booster supply hose to intake plenum.
9. Reconnect automatic idle speed motor and throttle position sensor wiring connectors. Connect vacuum/vapor hose harness to throttle body.
10. Install throttle cable and transaxle kickdown linkage (if equipped). Install air inlet hose assembly. Connect negative battery cable. Pressure test system for leaks.

1. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable.
2. Remove air cleaner-to-throttle body hose. Remove throttle cable. Remove wiring harness from throttle cable bracket and intake manifold water tube. Remove wiring connectors for automatic idle speed motor and throttle position sensor from throttle body.
3. Remove vacuum hose harness from throttle body. Remove PCV and brake booster hoses from air intake plenum. Remove EGR tube flange from intake plenum. Disconnect charge temperature sensor.
4. Remove vacuum harness connections from air intake plenum. Remove cylinder head-to-intake plenum strut. Disconnect MAP sensor and oxygen sensor electrical connectors.
5. Remove engine-mounted ground strap. Remove fuel hose quick-connect fitting from fuel rail by pushing in on plastic ring located on end of fittings. Gently pull fittings from fuel rail. WARNING: Wrap a shop towel around hoses to catch any spilled gasoline.
6. Remove direct ignition system coils. See IGNITION COIL under IGNITION SYSTEM. Remove alternator bracket-to-intake manifold bolt. Remove intake manifold bolts, and rotate manifold back over rear valve cover.
7. Cover intake manifold with a suitable cover when servicing. Remove vacuum hose harness connector from fuel pressure regulator. Remove fuel tube retainer bracket screw and fuel rail attaching bolts. Spread the retainer bracket to allow fuel tube removal clearance.
8. Remove fuel rail injector wiring clip from alternator bracket. Disconnect cam sensor, coolant temperature sensor and engine temperature sensor connectors.
9. Remove fuel rail. DO NOT damage rubber "O" rings on injectors when removing injectors from their ports. Replace "O" rings if damaged.

1. Ensure injectors are seated into receiver cups on rail with lock rings in place. See REMOVAL under FUEL INJECTORS. Ensure injector holes are clean and all plugs have been removed. Replace "O" rings if damaged.
2. Lubricate injector "O" rings with a drop of clean engine oil to ease installation. Push the tip of each injector into its port. Push entire assembly into place until injectors are seated in ports.
3. Install 4 fuel rail attaching bolts and tighten to 17 ft. lbs. (22 N.m). Install fuel tube retaining bracket screw and tighten to 35 INCH lbs. (4 N.m). Reconnect cam sensor, coolant temperature sensor and engine temperature sensor.
4. Reconnect fuel injector wiring harness to engine harness. Install fuel injector wiring harness wiring clips on alternator bracket and intake manifold water tube. Connect fuel pressure regulator vacuum hose. Remove covering on lower intake manifold, and clean manifold surface.
5. Place intake manifold gasket on lower manifold. Put upper manifold into place and install bolts finger tight. Install and finger tighten alternator bracket-to-intake manifold bolt and cylinder head-to-intake manifold strut bolts.
6. Tighten upper-to-lower intake manifold bolts to 21 ft. lbs. (28 N.m) following torque sequence. (Scheme 8) Tighten alternator bracket-to-intake manifold bolt to 40 ft. lbs. (54 N.m). Tighten cylinder head-to-intake manifold strut bolts to 40 ft. lbs. (54 N.m).
7. Install ground strap. Reconnect MAP sensor, oxygen sensor and charge temperature sensor electrical connectors. Connect vacuum hose harness to intake plenum.
8. Connect PCV system. Using a new gasket, connect EGR tube flange to intake manifold and tighten to 17 ft. lbs. (22 N.m).
9. Clip wiring harness into hole in throttle cable bracket. Connect wiring connectors to throttle position sensor and automatic idle speed motor. Connect vacuum harness to throttle body.
10. Install direct ignition system coils. See IGNITION COIL under IGNITION SYSTEM. Tighten fasteners to 105 INCH lbs. (12 N.m). Install fuel hose quick-connect fittings to fuel rail. Push each fitting onto rail until it clicks into place. Fuel supply fitting is 5/16" and fuel return fitting is 1/4".
11. Install throttle cable. Install air cleaner and hose assembly. Connect negative battery cable. Pressure test system for leaks.

Scheme 8

1. Remove air cleaner assembly. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove injector hold-down clamp Torx screw.
2. With 2 small screwdrivers, lift the top off injector using slots provided. (Scheme 9) Using a small screwdriver placed in hole in the front of electrical connector, gently pry injector from pod. Ensure lower "O" ring has been removed from pod.

Scheme 9

1. Place a new "O" ring on injector cap. New injector has new upper and lower "O" ring already installed. Apply a light coating of clean engine oil on "O" rings.
2. Place assembly in pod and align injector wiring terminals with injector cap fastener hole. (Scheme 10) Install injector cap with locating notch aligned with locating lobe on injector.
3. Push down on cap to ensure a good seal. Rotate cap and injector to line up attachment hole. Install Torx screw and tighten to 35-45 INCH lbs. (4-5 N.m). Reconnect negative battery cable. Pressure test system for leaks. Reinstall air cleaner assembly.

Scheme 10

1. Remove fuel rail. See FUEL INJECTOR RAILS (PFI). Disconnect injector wiring connector from injector. Position fuel rail assembly so fuel injectors are easily accessible.
2. Remove injector lock ring from fuel rail. (Scheme 11) Remove injector. Inspect injector "O" ring for damage. Replace "O" ring if damaged. If injector is to be reused, a protective cap must be installed on injector tip to prevent damage. Repeat for remaining injectors.

1. Lubricate "O" ring of each injector with a drop of clean engine oil to aid in installation. Install injector top end into fuel rail receiver cup. Be careful not to damage "O" ring during installation. Install injector lock ring.
2. Repeat for remaining injectors. Install wiring harness to injectors. Fasten wiring harness into wiring clips (if equipped).

Scheme 11

1. Remove air cleaner assembly. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove injector hold-down clamp Torx screw. (Scheme 12) CAUTION: DO NOT damage loose spacer under clamp.
2. Using a small screwdriver and the area in front of hold-down clamp for leverage, lift the caps off injectors. Using a small screwdriver placed in hole in front of electrical connector, gently pry the injectors from pods. (Scheme 13) Ensure each injector lower "O" ring has been removed from pod.

Scheme 12

Scheme 13

1. Install lower "O" ring on injector. "O" ring should butt against plastic filter assembly. Inspect both "O" rings for cuts or tears and replace if necessary. Align injector terminal housing with locating socket in injector cap.
2. Press injector into cap so upper "O" ring flange is flush with lower surface of cap. Spray inner surfaces of injector pod with Mopar Brake and Carburetor Parts Cleaner to remove residual gasoline.
3. Lightly lubricate upper and lower "O" rings with petroleum jelly. Place injector and cap in injector pod and align cap locating pin with locating hole in casting. (Scheme 13) CAUTION: Passenger side cap locating pin is 5 mm in diameter and will only fit in passenger side locating hole. Driver side locating pin is 4 mm in diameter.
4. Repeat steps 1 - 3 for other injector and cap. Press firmly on injector caps until flush with casting surface. Place injector hold-down clamp with spacer on rear portion of caps, aligning holes in clamp with pins on caps. Install clamp screw. Ensure spacer is in place. CAUTION: Because "O" ring may cause caps to lift up, press firmly on both caps with one hand to ensure caps are flush while installing clamp screw.
5. Tighten screw to 35 INCH lbs. (4 N.m). Connect negative battery cable. Pressure test system for leaks. Reinstall air cleaner assembly.

1. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove Direct Ignition System (DIS) coil pack electrical connector.
2. Remove DIS coil fasteners and rotate to access fuel pressure dampener. (Scheme 14) Disconnect fuel hose quick-connect fitting by pushing in on plastic ring located at end of fitting. Slide fitting off fuel tube.
3. Disconnect coolant temperature sensor electrical connector. Remove fuel rail retainer bracket screw.
4. Using 2 open-end wrenches, one on return tube nut and other on fuel rail hex, loosen tube nut. Use 2 wrenches to avoid damaging tube nut. Remove fuel pressure dampener.

Scheme 14

1. Insert and finger tighten return tube nut into fuel rail hex. Place fuel return tube into fuel rail retainer bracket. Insert fuel rail retainer bracket screw and tighten to 35 INCH lbs. (4 N.m).
2. Connect coolant temperature sensor electrical connector. Place DIS coils in position and install fasteners. Tighten to 105 INCH lbs. (12 N.m). Connect DIS coil 4-way electrical connector.
3. Insert fuel hose quick-connect fitting onto fuel tube until a click is heard. Pressure test system for leaks.

See FUEL INJECTOR RAILS (PFI). 1) Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove fuel pressure regulator vacuum connector.

2) Remove regulator retainer screw. Remove fuel pressure regulator retainer. Remove fuel pressure regulator.

1. Ensure fuel pressure regulator has 2 plastic spacers. Ensure fuel rail has 2 "O" rings installed in fuel pressure regulator cavity. (Scheme 15)
2. Lubricate "O" rings with clean engine oil. Insert fuel pressure regulator into fuel rail. Install fuel pressure regulator retainer.
3. Install retainer screw. Tighten to 50 INCH lbs. (5.6 N.m). Connect fuel pressure regulator vacuum connection. Pressure test system for leaks.

Scheme 15

1. Remove air cleaner assembly. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove vacuum hose from throttle body.
2. Remove screws attaching pressure regulator to throttle body. Remove pressure regulator from throttle body. Carefully remove "O" ring from pressure regulator. Remove gasket.

1. Place new gasket on pressure regulator and carefully install new "O" ring. Position pressure regulator on throttle body and press into place. Install mounting screws and tighten to 40 INCH lbs. (4.5 N.m).
2. Install vacuum hose to throttle body. Pressure test system for leaks. Reinstall air cleaner assembly.

1. Remove air cleaner and disconnect negative battery cable. Disconnect electrical connector.
2. Remove ISC motor attaching nuts. Remove ISC motor from bracket.

1. Install ISC to bracket. Attach electrical connector.
2. Start vehicle and allow to run for two minutes. Shut vehicle OFF. Wait 60 seconds for ISC shaft to extend completely. Disconnect wiring connector to ISC.
3. Disconnect coolant temperature sensor connector. Connect tachometer to engine. Start engine.
4. Adjust extension screw on ISC shaft until RPM is within specification. See «ISC SPEED SETTING»(ref-10656-S02637112392000111300000) table. ISC SPEED SETTING Vehicle Mileage Engine Speed RPM 3.9L Engine Less than 1000 miles 2650-2750 More than 1000 miles 2750-2850 5.2L & 5.9L Engines Less than 1000 miles 2650-2750 More than 1000 miles 2750-2850
5. Shut off vehicle. Reconnect ISC electrical connector. Reconnect coolant temperature sensor connector.

1. O2 sensor is mounted in exhaust pipe just below exhaust header. It is equipped with a permanent pigtail, which must be protected from damage when sensor is removed. Carefully disconnect engine harness from O2 sensor connector. DO NOT pull on oxygen sensor wiring when disconnecting sensor connector. Remove O2 sensor with Socket (C-4907). Sensor may be difficult to remove when engine temperature is less than 120°F (48°C).
2. Ensure sensor is free of contaminants; avoid using cleaning solvents of any type. Clean the threads in exhaust manifold with an 18 mmx1.5 x 6E tap. If installing original sensor, the sensor threads must be coated with an anti-seize compound. New O2 sensors are packaged with compound already on threads. Tighten sensor to 20 ft. lbs. (27 N.m).

1. Remove air cleaner. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Disconnect vacuum hoses and electrical connectors from throttle body.
2. Remove throttle cable, speed control cable and transmission kickdown cables (if equipped). Remove throttle return spring. Remove fuel intake and return hoses.
3. Remove throttle body mounting screws, and lift throttle body from vehicle. Remove throttle body gasket from intake manifold.

1. Using a new gasket, install throttle body and tighten mounting screws to 15 ft. lbs. (20 N.m). Install fuel intake and return hoses using new original-equipment type clamps.
2. Install throttle return spring. Install throttle cable. Install speed control and transmission kickdown cables (if equipped). Install wiring connectors and vacuum hoses. Install air cleaner. Reconnect negative battery cable.

1. Disconnect negative battery cable. Remove air cleaner-to-throttle body hose and clamp.
2. Remove throttle cable, speed control cables and transaxle linkage (if equipped). Disconnect wiring connectors for automatic idle speed motor and throttle position sensor. Disconnect vacuum hoses from throttle body.
3. Remove throttle body-to-intake manifold attaching nuts. Remove throttle body and gasket. To install, reverse removal procedure. Tighten throttle body attaching nuts to 19 ft. lbs (26 N.m).

Remove air cleaner. Disconnect throttle cables from throttle body linkage. Remove 2 screws from throttle cable bracket and lay bracket aside. Disconnect wiring connector by pulling downward. Unscrew sensor.

1. Apply heat transfer compound (provided with new sensor) to tip of new sensor. Install sensor and tighten to 110 INCH lbs. (12 N.m).
2. Connect electrical connector. Install throttle cable bracket with 2 screws. Connect throttle cables to throttle body linkage. Install air cleaner.

Remove air cleaner. Disconnect throttle body temperature sensor electrical connector. Remove sensor.

Apply heat transfer compound (provided with new sensor) to tip of new sensor. Install sensor and tighten to 110 INCH lbs. (12 N.m). Connect electrical connector. Install air cleaner.

Disconnect negative battery cable. Remove air cleaner (if necessary). Disconnect TPS electrical connector. Remove TPS mounting screws. Lift TPS off throttle shaft.

Install TPS on throttle body. Tighten mounting screws. See TORQUE SPECIFICATIONS table. Connect TPS electrical connector. Install air cleaner (if removed). Connect negative battery cable.