Engine Controls - Component Remove/install/overhaul - Diesel Dodge Cab & Chassis R2500

INTRODUCTION

Removal, overhaul and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

Removal & Installation

1. Disconnect negative battery cables. Disconnect electrical connectors from PCM. The PCM is located at passenger's side rear corner of engine compartment, on the firewall. (Scheme 1) Remove mounting bolts and PCM.
2. To install, reverse removal procedure. Tighten mounting bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications).

Scheme 1

INTERCOOLER

Note. Intercooler may also be referred to as charge air cooler.

Removal

1. Remove front bumper. Remove front support bracket located above center of intercooler. On A/C-equipped models, discharge A/C system using approved refrigerant recovery/recycling equipment.
2. Disconnect and plug hoses and openings at condenser. Remove condenser-to-intercooler screws and nuts. Remove condenser from front of intercooler. Plug all openings on condenser.
3. On all models, remove intercooler inlet and outlet ducts. (Scheme 2) Remove intercooler bolts. Pivot intercooler forward and upward to remove.

Inspection & Cleaning

1. Inspect intercooler for damaged fins or cracks. Replace intercooler if damaged. CAUTION: DO NOT use caustic cleaners to clean intercooler or intercooler may be damaged.
2. If intercooler cleaning is required, flush intercooler with a non-caustic solvent in the opposite direction of normal airflow. Use soft-faced hammer to lightly tap on end tanks on intercooler to dislodge any trapped material.
3. Continue flushing intercooler until all material is removed from intercooler. Use light to inspect inside of intercooler for remaining material.
4. Once intercooler is clean, wash intercooler with soap and hot water to remove remaining solvent. Once remaining solvent is removed, use clean water to rinse intercooler. Blow compressed air into intercooler in the opposite direction of the normal airflow until intercooler is dry.

Installation

To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . On A/C-equipped models, evacuate and charge A/C system.

Scheme 2

TURBOCHARGER

1. Disconnect negative battery cables. Disconnect air inlet tube and exhaust pipe from turbocharger. Disconnect intercooler inlet duct from turbocharger. (Scheme 2)
2. Disconnect and plug turbocharger oil supply line and turbocharger oil drain line at turbocharger. Remove turbocharger retaining nuts, turbocharger and gasket from exhaust manifold. Plug all air intake openings.

1. Apply anti-seize compound on turbocharger mounting studs. Using NEW gasket, install turbocharger. Install and tighten turbocharger retaining nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) .
2. Using NEW gasket, install turbocharger oil drain line on turbocharger. Install and tighten turbocharger oil drain line bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) . CAUTION: Turbocharger must be pre-lubricated by pouring clean engine oil in turbocharger oil supply line fitting on turbocharger before starting the engine. WARNING: DO NOT rotate turbine wheel in turbocharger with your finger, as sharp edges may exist.
3. Pour 3 ozs. (60 cc) of clean engine oil into turbocharger oil supply line fitting on turbocharger while using soft object to rotate turbine wheel in turbocharger. This must be done to pre-lubricate the turbocharger.
4. Install turbocharger oil supply line on turbocharger and tighten nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) . To install remaining components, reverse removal procedure. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) .

1. Engine coolant temperature sensor is located at front of cylinder head near thermostat. (Scheme 3)
2. Partially drain cooling system until coolant level is below the cylinder head. Disconnect ECT sensor electrical connector. Remove ECT sensor from cylinder head. Discard "O" ring. To install, reverse removal procedure. Use new "O" ring.

CRANKSHAFT POSITION SENSOR (CKP)

Note. Crankshaft Position (CKP) sensor may be referred to as engine speed sensor.

1. CKP sensor is located on left rear side of engine block near starter motor. (Scheme 3) Disconnect negative battery cables. Disconnect electrical wiring harness connector for CKP sensor.
2. Remove starter motor. Remove CKP sensor mounting bolt and bracket. Pull CKP sensor from engine block with a twisting motion. To install CKP sensor, reverse removal procedure. Tighten CKP bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications)

Scheme 3

1. Disconnect electrical connector from intake manifold air temperature sensor. (Scheme 3) Remove intake manifold air temperature sensor from intake manifold cover.
2. To install, reverse removal procedure. Tighten intake manifold air temperature sensor to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications).

Removal (A/T Models)

Raise and support vehicle. Disconnect electrical connector from park/neutral switch. Park/neutral switch is located on side of transmission case, near shift linkage. Unscrew park/neutral switch from transmission case. Remove seal ring from park/neutral switch.

1. Apply parking brake. Place shift lever in Park and Neutral. Ensure park/neutral switch operating levers in transmission are centered in the park/neutral switch opening on transmission case.
2. Using NEW seal ring, install park/neutral switch. Tighten park/neutral switch to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) . Install electrical connector. Add ATF as necessary.

ACCELERATOR PEDAL POSITION SENSOR (APPS)

Note. APPS is replaced as assembly, including lever, brackets, and sensor.

1. Disconnect negative battery cables. Remove cable cover. Using finger pressure only, disconnect end of speed control servo cable from throttle lever pin by pulling forward on connector while holding lever rearward. Using 2 small screwdrivers, pry throttle cable connector socket from throttle lever ball.
2. Disconnect transmission kickdown cable (if equipped). Compress pinch tabs on cruise control and throttle cables. Pull cables rearward to remove from cable mounting brackets. (Scheme 4) Disconnect electrical connector and retaining bolts. Remove APPS sensor.

To install, reverse removal procedure. To calibrate ECM, turn ignition on. Without starting engine, slowly press throttle pedal to floor and then slowly release.

Scheme 4

Fuel heater relay is located in Power Distribution Center (PDC). Check label under PDC cover for relay location. To install, reverse removal procedure.

1. Intake manifold air heater relays are mounted on inner wheelwell, below driver's side battery. (Scheme 5) Disconnect negative battery cables.
2. Note location of wiring on intake manifold air heater relays for installation reference. Disconnect electrical connectors at intake manifold air heater relays.
3. Remove retaining bolts and intake manifold air heater relay assembly. Both relays and mounting bracket are replaced as an assembly. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications).

Scheme 5

FUEL LINE DISCONNECT FITTINGS

Note. Fuel lines may contain single tab, dual tab or plastic retainer ring disconnect fitting. (Scheme 6) Determine type of disconnect fitting used and use proper procedure for proper disconnect fitting.

Scheme 6

Removal & Installation (Single Tab)

1. Disconnect negative battery cables. Ensure disconnect fitting and fuel lines are clean. Note location of release tab and pull tab on disconnect fitting. (Scheme 6) CAUTION: Release tab must be pressed downward before removing pull tab or pull tab will be damaged.
2. Press release tab downward. Use screwdriver to pry pull tab upward until pull tab separates from disconnect fitting. Remove disconnect fitting from fuel line. Inspect components for damage. If disconnect fitting is damaged, entire assembly must be replaced, as only pull tab can be replaced.
3. To install, ensure fuel line and disconnect fitting are clean. Lubricate fuel line and disconnect fitting with engine oil. Install disconnect fitting on fuel line until disconnect fitting bottoms on fuel line.
4. Install NEW pull tab until pull tab locks in disconnect fitting. DO NOT reuse old pull tab. Pull on fuel line and disconnect fitting to ensure components are properly locked together. Reconnect negative battery cables. Start engine and check for leaks.

Removal & Installation (Dual Tab)

1. Disconnect negative battery cables. Ensure disconnect fitting and fuel lines are clean. Note location of tabs on disconnect fitting. (Scheme 6)
2. Squeeze both tabs against disconnect fitting. Pull disconnect fitting from fuel line. The plastic retainer will remain on the fuel system component being serviced. The "O" rings and spacer will remain in the disconnect fitting.
3. Inspect components for damage. If disconnect fitting is damaged, entire assembly must be replaced. The only component that may be replaced is the plastic retainer. If plastic retainer must be removed from fuel system component, carefully release the plastic retainer from the fuel system component using 2 screwdrivers. Inspect plastic retainer for cracks or damage. Replace plastic retainer if defective.
4. To install, ensure fuel line and disconnect fitting are clean. Lubricate fuel line and disconnect fitting with engine oil. Install disconnect fitting on fuel line until click sound is heard.
5. Pull on fuel line and disconnect fitting to ensure components are properly locked together. Reconnect negative battery cables. Start engine and check for leaks.

Removal & Installation (Plastic Retainer Ring)

1. Disconnect negative battery cables. Ensure disconnect fitting and fuel lines are clean. Note location of plastic retainer ring on disconnect fitting. (Scheme 6) NOTE: Plastic retainer ring must be pressed evenly into disconnect fitting. If plastic retainer is not even, it will be difficult to remove disconnect fitting from fuel line.
2. Firmly push disconnect fitting toward the fuel line while pushing plastic retainer ring evenly into disconnect fitting. With plastic retainer ring fully depressed, pull disconnect fitting from fuel line.
3. Inspect components for damage. If disconnect fitting is damaged, entire assembly must be replaced.
4. To install, ensure fuel line and disconnect fitting are clean. Lubricate fuel line and disconnect fitting with engine oil. Install disconnect fitting on fuel line until click sound is heard.
5. Pull on fuel line and disconnect fitting to ensure components are properly locked together. Reconnect negative battery cables. Start engine and check for leaks.

FUEL LINE BLEEDING

Note. Fuel line bleeding is necessary if fuel injection pump is replaced, fuel filter/water separator is not filled with diesel fuel before installing or vehicle ran out off fuel. Bleed high-pressure fuel lines if connections are loosened or replaced. If engine has not been operated for an extended time, bleed fuel lines before next initial engine start-up.

1. Loosen banjo bolt holding low-pressure fuel supply line to side of fuel injection pump. Wrap a towel around banjo fitting to catch fuel. Crank engine quickly and release key before engine starts. This will operate fuel transfer pump for about 25 seconds.
2. If fuel is not present at fuel supply line after 25 seconds, turn ignition off. Repeat engine crank procedure until fuel is present at fuel supply line. Tighten banjo bolt at fuel supply line to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) . CAUTION: Ensure parking brake is applied and transmission is in Neutral before bleeding fuel injection pump or high-pressure fuel lines. DO NOT operate starter for more than 30 seconds when bleeding fuel injection pump or high-pressure fuel lines. Allow 2-minute intervals between starter operations.
3. To bleed air from fuel injection pump, ensure parking brake is applied and transmission is in Neutral, as engine may start when operating starter to bleed air from fuel injection pump. Operate starter for 30 seconds to bleed any trapped air in fuel injection pump.
4. To bleed high-pressure fuel lines, ensure parking brake is applied and transmission is in Neutral, as engine may start when operating starter to bleed high-pressure fuel lines. Loosen high-pressure fuel line nut at fuel injector.
5. Operate starter until steady fuel flow exists at high-pressure fuel line. Tighten high-pressure fuel line nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) . Start engine. Repeat procedure on each high-pressure fuel line until engine operates smoothly.

FUEL FILTER/WATER SEPARATOR & WATER-IN-FUEL SENSOR

Note. Vehicle also contains an in-tank fuel filter located on bottom of fuel tank module. For servicing procedure, see FUEL TANK MODULE & IN-TANK FUEL FILTER under FUEL SYSTEM.

Note. When fuel filter/water separator is being replaced, manufacturer recommends cleaning the pre-filter. See FUEL HEATER under FUEL SYSTEM for servicing of pre-filter.

1. Ensure engine is off. Place drain pan below drain tube at fuel filter/water separator. (Scheme 3) Rotate handle on drain valve forward, toward front of vehicle to DRAIN position. Drain valve is located near top of fuel filter/water separator. (Scheme 3) Once fuel is drained from fuel filter/water separator, rotate handle on drain valve back to CLOSE position.
2. Disconnect drain tube from drain valve. Disconnect electrical connector for Water-In-Fuel (WIF) sensor at bottom of fuel filter/water separator. (Scheme 3)
3. Support canister for fuel filter/water separator and remove canister nut from top of filter mounting head. (Scheme 3) Remove canister with fuel filter/water separator and seal ring from filter mounting head. Remove fuel filter/water separator from canister.
4. Remove "O" ring from top of shaft inside the canister. Remove bolts and drain valve from canister (if necessary).
5. Check the 2 probes inside the canister on end of WIF sensor for contamination. Clean probes if contaminated. If contamination cannot be removed from the probes, replace WIF sensor. If replacing WIF sensor, remove WIF sensor and "O" ring from canister.
6. Fuel heater is located inside fuel filter housing. Heater mounting plate, heating element, temperature sensor, and wiring harness are serviced as an assembly. Disconnect heater electrical connector from engine wiring harness near upper rear part of filter.
7. Disconnect electrical connector at end of 2-wire harness before attempting to pass harness through filter header. Remove clip retaining wires to connector. Remove wires from connector. Remove 3 fuel heater screws. Press on heater sealing grommet to remove heater from filter canister header. Pass wire through hole in filter header. Remove fuel heater.

1. Ensure inside of canister is clean. Using NEW "O" ring, install WIF sensor on canister (if removed). Tighten WIF sensor to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) .
2. Install drain valve on canister (if removed). Tighten drain valve-to-canister bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) .
3. Install NEW "O" ring on shaft inside canister. Coat "O" ring with diesel fuel. Install NEW fuel filter/water separator and NEW seal ring in canister. Coat seal ring with diesel fuel. NOTE: Canister for fuel filter/water separator should be filled with diesel fuel before installing. If canister cannot be filled with diesel fuel, low-pressure fuel lines must be bled after installation. CAUTION: When installing canister on filter mounting head, ensure tab areas on outside of canister align with tabs on filter mounting head. This must be done to prevent damage to canister and filter mounting head.
4. Fill canister for fuel filter/water separator with diesel fuel. Install canister with fuel filter/water separator on filter mounting head. Ensure canister fully engages with filter mounting head and tab areas on outside of canister align with tabs on filter mounting head.
5. Install and tighten canister nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) .
6. To install remaining components, reverse removal procedure. If canister was not filled with diesel fuel, bleed low-pressure fuel lines before starting engine. See «FUEL LINE BLEEDING»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__fuel-line-bleeding) under FUEL SYSTEM. Start engine and check for fuel leaks.

FUEL TANK MODULE & IN-TANK FUEL FILTER

Note. In-tank fuel filter is located on bottom of fuel tank module which also contains the fuel gauge sending unit. Fuel tank module is mounted on top of fuel tank.

1. Raise and support vehicle. Disconnect negative battery cables. Drain fuel tank. Remove fuel tank filler tube bolts from body. Support fuel tank with transmission jack. Remove fuel tank straps and heat shields (if equipped).
2. Slightly lower fuel tank for access to fuel lines and electrical connector at fuel tank module. Disconnect electrical connector and fuel lines at fuel tank module. (Scheme 7) Use proper procedure when disconnecting fuel lines. See «FUEL LINE DISCONNECT FITTINGS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__fuel-line-disconnect-fittings) under FUEL SYSTEM. NOTE: Information for servicing of in-tank fuel filter is not available from manufacturer. If necessary to service in-tank fuel filter, consult parts department to verify if filter may be replace without replacing fuel tank module.
3. Note direction of fuel line connections on fuel tank module for installation reference. Using Spanner Wrench (6856), unscrew plastic fuel tank module lock nut from fuel tank. Remove fuel tank module and gasket from fuel tank. Inspect in-tank fuel filter for damage.

1. Using NEW gasket, install fuel tank module in fuel tank. Install plastic fuel tank module lock nut finger tight. DO NOT tighten plastic fuel tank module lock nut at this time.
2. Position fuel tank module so fuel line connections and electric connection are facing toward driver's side of vehicle. This must be done to prevent float on fuel gauge sending unit from contacting fuel tank.
3. Once fuel tank module is properly positioned, tighten plastic fuel tank module lock nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) .
4. Install fuel lines on fuel tank module using proper procedure. See «FUEL LINE DISCONNECT FITTINGS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__fuel-line-disconnect-fittings) under FUEL SYSTEM. Install electrical connector on fuel tank module. Reinstall fuel tank. Tighten fuel tank strap nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) . Reconnect negative battery cables.

Scheme 7

1. Remove nameplate located above rocker lever covers. Remove fuel injector drain line-to-fuel injector banjo bolt and seal washer from each fuel injector. Plug all fuel openings.
2. Remove fuel injector drain line assembly retaining clamp at rear of intake manifold. Remove fuel injector drain line bolt with seal washers at filter mounting head. (Scheme 3) Remove fuel injector drain line assembly.

To install, reverse removal procedure using NEW seal washers. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Fuel heater is located in FUEL FILTER/WATER SEPARATOR & WATER-IN-FUEL SENSOR. See FUEL FILTER/WATER SEPARATOR & WATER-IN-FUEL SENSOR .

Scheme 8

1. Disconnect negative battery cables. Each fuel injector is connected to each high-pressure fuel line with a steel connector line. Steel connector is positioned into cylinder head and sealed with "O" ring. (Scheme 8) If removing injector at cylinder No. 1 or No. 2, remove intake manifold air heater assembly. If removing injector at cylinder No. 5, remove engine lifting bracket.
2. Ensure area around fuel injector and high-pressure fuel line is clean. Disconnect high-pressure fuel line at fuel injector. DO NOT bend any high-pressure fuel line to gain access to fuel injector. It may be necessary to remove high-pressure fuel lines from fuel injection pump for access to fuel injector.
3. If removing high-pressure fuel lines from fuel injection pump, mark high-pressure fuel line location for installation reference. Remove valve cover. Thread Fuel Injector Connector Tube Remover (8324) onto end of injector connector tube. Pull injector connector tube from cylinder head. CAUTION: Injector connector tube must be removed before attempting to remove fuel injector or serious damage to fuel injector and tube will result.
4. Remove and discard old "O" ring from injector connector tube. Remove fuel injector hold down clamp bolt at front end of clamp. DO NOT loosen or remove shouldered bolt at rear of clamp. Remove injector clamp by sliding it from shoulders on rear clamp bolt. Thread rod from Fuel Injector Remover (8318) into top of fuel injector. Tighten nut on fuel injector remover to remove fuel injector from cylinder head. Remove and discard "O" ring and copper sealing washer.

1. Clean fuel injector bore on cylinder head with wire brush. Apply light coat of engine oil on NEW .060" (1.5 mm) thick Copper sealing washer. Install NEW Copper sealing washer on spray tip of fuel injector. Engine oil is used to aid holding sealing washer in place. Install new "O" ring on fuel injector. Apply small amount of engine oil to "O" ring.
2. Ensure fuel inlet hole on side of fuel injector is positioned toward injector connector tube. Install injector into cylinder head bore using care not to allow injector tip to touch sides of bore. Press fuel injector into cylinder head with finger pressure only. Install fuel injector hold down clamp into shouldered bolt while aligning slot in top of injector into groove in bottom of clamp. Tighten opposite clamp bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) .
3. Apply small amount of clean engine oil to NEW "O" ring. Install "O" ring to fuel injector connector tube. Using finger pressure only, press injector connector tube into cylinder head. Connect and tighten high pressure fuel lines to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) . NOTE: Fuel line fitting torque is important. Mating surfaces will not seal if fuel line fitting is under or over-torqued.
4. To install remaining components, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) . Bleed high-pressure fuel lines. See «FUEL LINE BLEEDING»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__fuel-line-bleeding) under FUEL SYSTEM.

FUEL INJECTION PUMP

Scheme 9

1. Disconnect negative battery cables. Clean fuel lines at cylinder head and injection pump. Clean fuel injection pump and fuel lines at side of pump. Disconnect 9-pin electrical connector at Fuel Pump Control Module (FPCM). Place a rag around overflow valve to catch excess fuel. Remove overflow valve and disconnect fuel return line. Remove banjo bolts and fuel supply line at side of injection pump and top of fuel filter housing.
2. Remove all high pressure fuel lines, intake air tube, accelerator pedal position sensor, air intake housing, engine oil dipstick tube, wiring clips, electrical connectors at intake heaters, and engine lifting bracket. Unscrew plastic access cap at front gear cover. Remove injection pump gear-to-injection pump shaft nut and washer.
3. Engine may be rotated by removing dust plug from transmission adapter plate and installing Engine Barring Tool (Snap-On SP371) in transmission adapter plate. (Scheme 9) Rotate engine until keyway is at 12 o'clock position. CAUTION: Engine must be rotated until keyway is at 12 o'clock position to prevent pump/gear keyway from falling into gear housing. If gear retainer nut, washer or key drops into gear housing, cover may have to be removed to retrieve them before engine start.
4. Using gear puller, separate injection pump gear from injection pump shaft. (Scheme 11) DO NOT pull fuel injection pump drive gear too far forward or timing gear cover may be damaged.
5. Remove 3 lower fuel injection pump-to-lower mounting bracket bolts. Loosen 2 engine bracket bolts. (Scheme 10) Remove 4 fuel injection pump-to-gear housing nuts. Remove fuel injection pump. Use care not to scratch or damage shaft of fuel injection pump during removal.

Scheme 10

Scheme 11

Note. Before installing fuel injection pump, ensure shaft on fuel injection pump is properly positioned for proper fuel injection pump timing, cylinder No. 1 at TDC on compression stroke and timing pin is engaged in machined hole on camshaft gear.

Scheme 12

1. Check pump mounting surfaces at pump and mounting flange for nicks, cuts or damage. Check "O" ring surfaces for nicks, cuts or damage. Clean injection pump mounting flange at gear housing. Clean front of injection pump. Install new "O" ring on pump mounting area. Apply clean engine oil to injection pump "O" ring only. CAUTION: Ensure fuel injection pump drive gear-to-shaft mating surfaces are clean and free of oil to provide proper seating of fuel injection pump drive gear on shaft of fuel injection pump.
2. Pump/gear keyway has an arrow and 3-digit number stamped at top edge. (Scheme 12) Position keyway into pump shaft with arrow pointed toward rear of pump. Ensure 3-digit number stamped on top of keyway is identical as 3-digit number stamped on injection pump data plate. If incorrect keyway is installed, a Diagnostic Trouble Code (DTC) may be set.
3. Position pump assembly to mounting flange on gear cover while aligning injection pump shaft through back of injection pump gear. When installing pump, ensure dowel on mounting flange must align with hole in front of pump. Ensure fuel injection pump is flat against gear housing. Install 4 fuel injection pump-to-gear housing nuts finger tight. DO NOT tighten nuts at this time. CAUTION: DO NOT tighten pump to gear cover using mounting nuts. Damage to pump or gear cover may result. Pump must be positioned flat to mounting flange before attempting to tighten mounting nuts.
4. Install fuel injection pump shaft washer and nut to pump shaft finger tight. Position lower pump bracket and install 3 bolts finger tight. Tighten fuel injection pump drive gear nut to preliminary torque of 22 ft. lbs. (30 N.m). Tighten 4 fuel injection pump nuts and 3 lower pump bracket-to-pump bolts to specification. Tighten 2 engine bracket-to-engine bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) Final tighten injection pump shaft nut. Use barring tool to prevent engine from rotating.
5. Install plastic access cap to front gear cover. Using new gaskets, install fuel return line and overflow valve to side of injection pump. Tighten overflow valve to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) Using new gaskets, install fuel supply line to side of injection pump and top of fuel filter housing. Tighten banjo bolts to specification. «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications).
6. To complete installation, reverse removal procedure. Bleed air from fuel system. See «FUEL LINE BLEEDING»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__fuel-line-bleeding).

1. Fuel tank rollover valve is pressed into rubber grommet on top of fuel tank module. (Scheme 7) Manufacturer recommends removing fuel tank for access to fuel tank rollover valve. NOTE: It may be necessary to disconnect fuel lines and electrical connector from fuel tank module so fuel tank may be lowered for access to fuel tank rollover valve.
2. Raise and support vehicle. Disconnect negative battery cables. Drain fuel tank. Remove fuel tank filler tube bolts from body. Support fuel tank with transmission jack. Remove fuel tank straps and heat shields (if equipped). NOTE: Manufacturer recommends replacing rubber grommet on fuel tank module when servicing fuel tank rollover valve.
3. Slightly lower fuel tank for access to fuel tank rollover valve. Disconnect electrical connector and fuel lines from fuel tank module if necessary to gain access to fuel tank rollover valve. Use proper procedure when disconnecting fuel lines. See «FUEL LINE DISCONNECT FITTINGS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__fuel-line-disconnect-fittings) under FUEL SYSTEM.
4. Disconnect hose from fuel tank rollover valve. Pry one side of fuel tank rollover valve from rubber grommet. Remove fuel tank rollover valve. Remove rubber grommet.

1. To install, reverse removal procedure using NEW rubber grommet. If fuel lines were disconnected, install fuel lines on fuel tank module using proper procedure. See «FUEL LINE DISCONNECT FITTINGS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__fuel-line-disconnect-fittings) under FUEL SYSTEM.
2. Reinstall fuel tank. Tighten fuel tank strap nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) . Reconnect negative battery cables.

1. Disconnect negative battery cables. Clean area around transfer pump and fuel lines. Remove starter. Place a drain pan below pump. Disconnect fuel line fitting at fuel supply line. Remove support bracket bolt at top of pump. Remove banjo bolts at front and rear of pump.
2. Disconnect pigtail harness electrical connector from main engine wiring harness. Remove 3 pump bracket nuts. Remove fuel transfer pump.

1. Install new gaskets to fuel supply line, support bracket, and banjo bolt at rear of pump. Install banjo bolt finger tight. Install new gaskets to fuel line and banjo bolt at front of pump. Position 3 pump studs into pump mounting bracket and install 3 nuts finger tight. Install support bracket bolt finger tight.
2. Tighten bolts and nuts evenly to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) . Reconnect electrical connectors. Tighten fuel lines to specification. Install starter and negative battery cables. Bleed low-pressure fuel lines. See «FUEL LINE BLEEDING»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__fuel-line-bleeding) under FUEL SYSTEM.

HIGH-PRESSURE FUEL LINES

1. Disconnect negative battery cables. Remove nameplate located above rocker lever covers. Disconnect necessary clamps from high-pressure fuel lines.
2. Ensure area around each high-pressure fuel line nut is clean. Mark high-pressure fuel line location for installation reference. Remove high-pressure fuel line from fuel injector.
3. Remove high-pressure fuel lines from fuel injection pump. Remove high-pressure fuel lines from engine, using care not to bend the fuel line.

To install, reverse removal procedure. Ensure all high-pressure fuel line nuts are tightened to specification at fuel injector and fuel injection pump before tightening clamp bolts to specification. Bleed high-pressure fuel lines. See FUEL LINE BLEEDING under FUEL SYSTEM.

1. Disconnect negative battery cables. Ensure area around overflow valve is clean. Remove valve from pump and banjo fitting. Discard gaskets.
2. To install, reverse removal procedure using NEW gaskets. Tighten overflow valve to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications) .

Scheme 13

1. Disconnect negative battery cables. Disconnect clamp and rubber hose at air intake housing. Remove engine oil dipstick tube mounting bolt and position dipstick tube aside. Disconnect heater electrical cables at cable mounting studs. Remove 4 air intake housing bolts. Remove air intake housing from top of intake manifold air heater elements. (Scheme 13)
2. Remove heater element assembly from intake manifold. Clean old gasket from air intake housing, intake manifold, and both sides of engine block. To install, reverse removal procedure using NEW gaskets. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r2500/1996-2002/remont/removal-installation/#engine-controls-component-removeinstalloverhaul-diesel__torque-specifications).

See INTAKE MANIFOLD AIR HEATER RELAYS under RELAYS & SOLENOIDS.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TORQUE SPECIFICATIONS
• INTERCOOLER
• FUEL TANK MODULE & IN-TANK FUEL FILTER
• FUEL HEATER
• FUEL LINE BLEEDING
• FUEL LINE DISCONNECT FITTINGS
• FUEL FILTER/WATER SEPARATOR & WATER-IN-FUEL SENSOR