Engine Controls - On-Vehicle Adjustments - Diesel Dodge Cab & Chassis R2500

ENGINE MECHANICAL

Before performing any on-vehicle adjustments to fuel system, ensure engine mechanical condition is okay.

VALVE CLEARANCE

Note. Valve clearance must be adjusted with engine temperature less than 140°F (60°C).

Scheme 4

Scheme 5

1. Disconnect negative battery cables. Remove valve cover. Remove fuel pump gear access cover, located at front of engine. Using Engine Barring Tool (7471B), rotate engine to align pump gear mark with TDC mark on gear housing cover. (Scheme 4)
2. With cylinder No. 1 at TDC, check valve clearance on proper valves. Perform STEP 1. (Scheme 5) See «VALVE CLEARANCE ADJUSTING SEQUENCE»(/dodge/cab-chassis-r2500/1996-2002/remont/adjustments/#engine-controls-on-vehicle-adjustments-diesel) table. Using feeler gauge, check valve clearance between rocker arm socket and crosshead. Ensure valve clearance is within specification. See «VALVE CLEARANCE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/adjustments/#engine-controls-on-vehicle-adjustments-diesel) table. If valve clearance is within specification, go to next step. If any valve clearance is not within specification, loosen rocker lever adjusting screw lock nut, and adjust valve clearance by rotating rocker lever adjusting screw. Tighten rocker lever adjusting screw lock nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/adjustments/#engine-controls-on-vehicle-adjustments-diesel__torque-specifications). When all valve clearances are within specification, go to next step. VALVE CLEARANCE ADJUSTING SEQUENCE Procedure Cylinders No. Step 1 (1) Intake Valve 1, 2 & 4 Exhaust Valve 1, 3 & 5 Step 2 (2) Intake Valve 3, 5 & 6 Exhaust Valve 2, 4 & 6 (1) Perform STEP 1. (Scheme 5) (2) Rotate engine clockwise (viewed from front of engine) one full revolution from TDC on cylinder No. 1 (STEP 1) and align reference marks. Perform STEP 2. (Scheme 5) VALVE CLEARANCE SPECIFICATIONS (1) Application In. (mm) Intake Valve (2).006-.015 (.152-.381) Exhaust Valve (3).015-.030 (.381-.762) (1) Adjust valve clearance with engine temperature less than 140°F (60°C). (2) Set to.010" (.254 mm) if adjustment is necessary. (3) Set to.020" (.508 mm) if adjustment is necessary.
3. Rotate engine clockwise (viewed from front of engine) one full revolution from TDC on cylinder No. 1 and align reference marks. Check valve clearance on proper valves. Perform STEP 2. (Scheme 5) See «VALVE CLEARANCE ADJUSTING SEQUENCE»(/dodge/cab-chassis-r2500/1996-2002/remont/adjustments/#engine-controls-on-vehicle-adjustments-diesel) table. Ensure valve clearance is within specification. See «VALVE CLEARANCE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/adjustments/#engine-controls-on-vehicle-adjustments-diesel) table. If valve clearance is within specification, go to next step. If valve clearance is not within specification, loosen rocker lever adjusting screw lock nut, and adjust valve clearance by rotating rocker lever adjusting screw. Tighten rocker lever adjusting screw lock nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/adjustments/#engine-controls-on-vehicle-adjustments-diesel__torque-specifications). Go to next step.
4. Install valve cover, fuel pump access cover and battery cables.

CHECKING FUEL INJECTION PUMP TIMING

Note. With Bosch VP 44 pump, no mechanical adjustments are necessary. All timing and fuel adjustments are performed by Engine Control Module (ECM). If a DTC indicating engine sync error or static timing error has been set, perform following adjustment. If DTC sets after installing a new pump, pump keyway has probably been installed backward.

Scheme 6

Scheme 7

1. Remove fuel pump access cover, shaft nut and washer. Ensure keyway aligning pump shaft to pump gear has not slipped. If keyway has slipped, repair as necessary.
2. Remove timing gear cover. See REMOVAL, OVERHAUL & INSTALLATION - TRUCKS - DIESEL article. Using a T-type puller, remove injection pump gear from shaft. Ensure key has been installed in keyway with arrow pointing to rear of pump. Pump timing is calibrated to pump keyway. Ensure 3-digit number on key matches number on pump data plate. (Scheme 6) There are 21 different calibrations available. Repair as necessary.
3. Reinstall pump timing gear. Ensure timing marks on crankshaft gear, camshaft gear and fuel pump gear are aligned. (Scheme 7) Repair as necessary. After repairs are done, clear DTCs.

IDLE SPEED

Idle speed is controlled by Engine Control Module (ECM). Idle speed is not adjustable.

THROTTLE POSITION SENSOR ADJUSTMENT

Throttle position sensor may also be referred to as Acceleration Pedal Position Sensor (APPS). Throttle Position (TP) sensor is not adjustable.

CONTROL ROD ADJUSTMENT

Note. Manufacturer does not provide adjustment information.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• VALVE CLEARANCE ADJUSTING SEQUENCE
• TORQUE SPECIFICATIONS