Fuel Injection: Other Dodge Durango II

Without APPS

The following procedure applies only to vehicles without the Adjustable Pedal Package (code XAP). It also applies to vehicles not equipped with an accelerator pedal position sensor.

The accelerator pedal is serviced as a complete assembly including the bracket.

The accelerator cable is connected to the upper part of the accelerator pedal arm by a plastic retainer (clip) (7). This plastic retainer snaps into the top of the accelerator pedal arm.

Scheme 7

1. From inside the vehicle, hold up accelerator pedal. Remove plastic cable retainer (clip) (7) and throttle cable core wire from upper end of accelerator pedal arm (6). Plastic cable retainer (clip) snaps into pedal arm.
2. Remove two accelerator pedal mounting bracket nuts (5). Remove accelerator pedal assembly (4).

With APPS

The following procedure applies only to vehicles without the Adjustable Pedal Package (code XAP). It also applies to vehicles equipped with an accelerator pedal position sensor (6).

The accelerator pedal (4) is serviced as a complete assembly including the bracket.

Scheme 8

1. Disconnect electrical connector (1) at APPS (6).
2. Remove two accelerator pedal mounting bracket nuts (5). Remove accelerator pedal assembly (4).

The following procedure applies only to vehicles without the Adjustable Pedal Package (code XAP). It also applies to vehicles not equipped with an accelerator pedal position sensor.

The accelerator pedal is serviced as a complete assembly including the bracket.

The accelerator cable is connected to the upper part of the accelerator pedal arm by a plastic retainer (clip) (7). This plastic retainer snaps into the top of the accelerator pedal arm.

Scheme 9

1. Place accelerator pedal assembly (4) over two mounting studs (3).
2. Install and tighten two mounting nuts (5). Refer to «TORQUE - FUEL SYSTEM»(ref-564649-S26967950632013070500000) .
3. Slide throttle cable into opening slot (6) in top of pedal arm.
4. Push plastic cable retainer (clip) (7) into accelerator pedal arm opening until it snaps into place.
5. Before starting engine, operate accelerator pedal to check for any binding.

The following procedure applies only to vehicles without the Adjustable Pedal Package (code XAP). It also applies to vehicles equipped with an accelerator pedal position sensor (6).

The accelerator pedal is serviced as a complete assembly including the bracket.

Scheme 10

1. Place accelerator pedal assembly (4) over two mounting studs (3).
2. Install and tighten two mounting nuts (5). Refer to «TORQUE - FUEL SYSTEM»(ref-564649-S26967950632013070500000) .
3. Install electrical connector (1) to APPS (6).
4. A Scan Tool may be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn.
5. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set.
6. If necessary, use a scan tool to erase any Diagnostic Trouble Codes (DTC's) from PCM.
7. Before starting engine, operate accelerator pedal to check for any binding.

3.7LV-6

The Crankshaft Position (CKP) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole.

4.7LV-8

The Crankshaft Position (CKP) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole.

5.7LV-8

The Crankshaft Position (CKP) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole.

3.7L V-6

Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing.

The sensor (3) is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it.

A tonewheel (targetwheel) is bolted to the engine crankshaft (1). This tonewheel has sets of notches (2) at its outer edge.

The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM.

Scheme 11

Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the power-train control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing.

The sensor (3) is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it.

On the 4.7L V-8 engine, a tonewheel (1) is bolted to the engine crankshaft. This tonewheel has sets of notches (2) at its outer edge.

The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM.

Scheme 12

5.7L V-8

Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the power-train control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing.

The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it.

On the 5.7L V-8 engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge.

The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM.

Scheme 13

The Crankshaft Position (CKP) sensor (2) is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole.

Scheme 14

1. Raise vehicle.
2. Disconnect sensor electrical connector.
3. Remove sensor mounting bolt (1).
4. Carefully twist sensor from cylinder block.
5. Check condition of sensor o-ring (3).

4.7L V-8

The Crankshaft Position (CKP) sensor (.1) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block.

Scheme 15

1. Raise vehicle.
2. Disconnect CKP electrical connector at sensor.
3. Remove CKP mounting bolt (2).
4. Carefully twist sensor from cylinder block.
5. Remove sensor from vehicle.
6. Check condition of sensor o-ring.

The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block (1). It is positioned and bolted into a machined hole in the engine block.

Scheme 16

1. Raise vehicle.
2. Disconnect CKP electrical connector (2) at sensor.
3. Remove CKP mounting bolt (3).
4. Carefully twist sensor from cylinder block.
5. Remove sensor from vehicle.
6. Check condition of sensor o-ring.

1. Clean out machined hole in engine block.
2. Apply a small amount of engine oil to sensor o-ring.
3. Install sensor into engine block with a slight rocking and twisting action. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result.
4. Install mounting bolt and tighten to 28 N.m (21 ft. lbs.) torque.
5. Connect electrical connector to sensor.
6. Lower vehicle.

1. Clean out machined hole in engine block.
2. Apply a small amount of engine oil to sensor o-ring.
3. Install sensor into engine block with a slight rocking and twisting action. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result.
4. Install mounting bolt and tighten to 28 N.m (21 ft. lbs.) torque.
5. Connect electrical connector to sensor.
6. Lower vehicle.

1. Clean out machined hole in engine block.
2. Apply a small amount of engine oil to sensor o-ring.
3. Install sensor into engine block with a slight rocking and twisting action. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result.
4. Install mounting bolt and tighten to 28 N.m (21 ft. lbs.) torque.
5. Connect electrical connector to sensor.
6. Lower vehicle.

The Idle Air Control (IAC) motor (3) is located on the side of the throttle body.

Scheme 17

1. Remove air resonator box at throttle body.
2. Disconnect electrical connector from IAC motor.
3. Remove two mounting bolts (screws).
4. Remove IAC motor from throttle body.

The Idle Air Control (IAC) motor (3) is located on the side of the throttle body.

Scheme 18

1. Remove air resonator box at throttle body.
2. Disconnect electrical connector from IAC motor.
3. Remove two mounting bolts (screws).
4. Remove IAC motor from throttle body.

The IAC motor is not serviceable on the 5.7L V-8 engine.

1. Install IAC motor to throttle body.
2. Install and tighten two mounting bolts (screws) to 7 N.m (60 in. lbs.) torque.
3. Install electrical connector.
4. Install air resonator to throttle body.

1. Install IAC motor to throttle body.
2. Install and tighten two mounting bolts (screws) to 7 N.m (60 in. lbs.) torque.
3. Install electrical connector.
4. Install air resonator to throttle body.

The IAC motor is not serviceable on the 5.7L V-8 engine.

The intake manifold air temperature (IAT) sensor (1) is installed into the left side of intake manifold plenum.

Scheme 19

Scheme 20

1. Disconnect electrical connector (3) from IAT sensor.
2. Clean dirt from intake manifold at sensor base.
3. Gently lift on small plastic release tab (3) and rotate sensor about 1/4 turn counter-clockwise for removal.
4. Check condition of sensor o-ring (2).

The intake manifold air temperature (IAT) sensor (3) is installed into the left side of intake manifold plenum.

Scheme 21

1. Disconnect electrical connector from IAT sensor.
2. Clean dirt from intake manifold at sensor base.
3. Gently lift on small plastic release tab (4) and rotate sensor about 1/4 turn counter-clockwise for removal.
4. Check condition of sensor o-ring.

The intake manifold air temperature (IAT) sensor is installed into the front of the intake manifold air box plenum (2).

Scheme 22

1. Disconnect electrical connector (2) from IAT sensor.
2. Clean dirt from intake manifold at sensor base.
3. Gently lift on small plastic release tab (3) and rotate sensor about 1/4 turn counter-clockwise for removal.
4. Check condition of sensor o-ring.

1. Check condition of sensor o-ring.
2. Clean sensor mounting hole in intake manifold.
3. Position sensor into intake manifold and rotate clockwise until past release tab.
4. Install electrical connector.

1. Check condition of sensor o-ring.
2. Clean sensor mounting hole in intake manifold.
3. Position sensor into intake manifold and rotate clockwise until past release tab.
4. Install electrical connector.

1. Check condition of sensor o-ring.
2. Clean sensor mounting hole in intake manifold.
3. Position sensor into intake manifold and rotate clockwise until past release tab.
4. Install electrical connector.

The Manifold Absolute Pressure (MAP) sensor is mounted into the front of the intake manifold with 2 screws.

The Manifold Absolute Pressure (MAP) sensor is mounted into the front of the intake manifold with 2 screws.

The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box.

The Manifold Absolute Pressure (MAP) sensor (2) is mounted into the front of the intake manifold.

Scheme 23

Scheme 24

1. Disconnect electrical connector at sensor.
2. Clean area around MAP sensor.
3. Remove two sensor mounting screws (1).
4. Remove MAP sensor from intake manifold.
5. Check condition of sensor o-ring (2)

The MAP sensor (3) is located on the front of the intake manifold. An o-ring seals the sensor to the intake manifold.

Scheme 25

1. Disconnect electrical connector at sensor.
2. Clean area around MAP sensor.
3. Remove two sensor mounting bolts (2).
4. Remove MAP sensor from intake manifold.
5. Check condition of sensor o-ring.

The Manifold Absolute Pressure (MAP) sensor (1) is mounted to the front of the intake manifold air plenum box.

Scheme 26

1. Disconnect electrical connector at sensor by sliding release lock out (1). Press down on lock tab (2) for removal.
2. Rotate sensor 1/4 turn counter-clockwise for removal.
3. Check condition of sensor o-ring.

The Manifold Absolute Pressure (MAP) sensor is mounted into the front of the intake manifold. An o-ring is used to seal the sensor to the intake manifold.

1. Clean MAP sensor mounting hole at intake manifold.
2. Check MAP sensor o-ring seal for cuts or tears.
3. Position sensor into manifold.
4. Install MAP sensor mounting bolts (screws). Refer to «TORQUE - FUEL SYSTEM»(ref-564649-S26967950632013070500000) .
5. Connect electrical connector.

The MAP sensor is located on the front of the intake manifold. An o-ring seals the sensor to the intake manifold.

1. Clean MAP sensor mounting hole at intake manifold.
2. Check MAP sensor o-ring seal for cuts or tears.
3. Position sensor into manifold.
4. Install MAP sensor mounting bolts (screws). Refer to «TORQUE - FUEL SYSTEM»(ref-564649-S26967950632013070500000) .
5. Connect electrical connector.

The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box.

1. Clean MAP sensor mounting hole at intake manifold.
2. Check MAP sensor o-ring seal for cuts or tears.
3. Position sensor into manifold.
4. Rotate sensor 1/4 turn clockwise for installation.
5. Connect electrical connector.

5.7L V-8 Engine

The throttle body on the 5.7L engine is an electrically controlled unit. A mechanical cable is not used to connect the throttle body to the accelerator pedal. The Accelerator Pedal Position Sensor (APPS) along with inputs from other sensors sets the throttle blade to pre-determined positions.

Except 5.7L V-8 Engine

Certain sensors are attached to the throttle body. The accelerator pedal cable, speed control cable and transmission control cable (when equipped) are connected to the throttle body linkage arm.

A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the PCM.

A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the Powertrain Control Module (PCM).

Scheme 27

Scheme 28

1. Remove air cleaner tube at throttle body.
2. Disconnect throttle body electrical connectors at IAC motor and TPS.
3. Remove all control cables from throttle body (lever) arm. Refer to «CABLE-THROTTLE CONTROL»(ref-212820-S06595869012005122700000) .
4. Disconnect necessary vacuum lines at throttle body.
5. Remove three throttle body mounting bolts (2).
6. Remove throttle body from intake manifold.
7. Check condition of old throttle body-to-intake manifold o-ring (2).

Scheme 29

1. Remove air duct and air resonator box at throttle body.
2. Disconnect throttle body electrical connectors at IAC motor and TPS (3), (4), and (5).
3. Remove vacuum line at throttle body.
4. Remove all control cables from throttle body (lever) arm. Refer to «CABLE-THROTTLE CONTROL»(ref-212820-S06595869012005122700000) .
5. Remove three throttle body mounting bolts (1).
6. Remove throttle body from intake manifold.

Scheme 30

Scheme 31

1. Remove air duct and air resonator box at throttle body.
2. Disconnect electrical connector at throttle body (2).
3. Remove four throttle body mounting bolts (4).
4. Remove throttle body from intake manifold.
5. Check condition of throttle body o-ring (2).

1. Check condition of throttle body-to-intake manifold o-ring. Replace as necessary.
2. Clean mating surfaces of throttle body and intake manifold.
3. Install throttle body-to-intake manifold o-ring.
4. Install throttle body to intake manifold.
5. Install 3 mounting bolts. Tighten bolts to 12 N.m (105 in. lbs.) torque.
6. Install control cables.
7. Install electrical connectors.
8. Install necessary vacuum lines.
9. Install air plenum.

1. Clean throttle body-to-intake manifold o-ring.
2. Clean mating surfaces of throttle body and intake manifold.
3. Install throttle body to intake manifold by positioning throttle body to manifold alignment pins.
4. Install three mounting bolts. Tighten bolts to 12 N.m (105 in. lbs.) torque.
5. Install control cables.
6. Install vacuum line to throttle body.
7. Install electrical connectors.
8. Install air plenum.

1. Clean and check condition of throttle body-to-intake manifold o-ring.
2. Clean mating surfaces of throttle body and intake manifold.
3. Install throttle body to intake manifold by positioning throttle body to manifold alignment pins.
4. Install 4 mounting bolts. Refer to «TORQUE - FUEL SYSTEM»(ref-564649-S26967950632013070500000) .
5. Install electrical connector.
6. Install air plenum.
7. A Scan Tool may be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn.
8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set.
9. If necessary, use a scan tool to erase any Diagnostic Trouble Codes (DTC's) from PCM.

Scheme 32

Scheme 33

Scheme 34

1. From inside vehicle, hold up accelerator pedal. Remove plastic cable retainer (clip) (7) and throttle cable core wire from upper end of pedal arm (6). Plastic cable retainer snaps into top of pedal arm.
2. Remove cable core wire at pedal arm.
3. From inside vehicle, remove metal clip (2) holding cable to dashpanel.
4. Remove air resonator box at throttle body.
5. Unsnap cable from dashpanel routing clip.
6. Remove cable housing from dash panel and pull into engine compartment.
7. Hold throttle in wide open position. While held in this position, slide throttle cable pin (1) from throttle body bellcrank.
8. Using a pick or small screwdriver (3), press release tab (2) to release plastic cable mount from bracket. Press on tab only enough to release cable from bracket. If tab is pressed too much, it will be broken. Slide plastic mount (4) towards right side of vehicle to remove throttle cable from throttle body bracket.
9. Remove throttle cable from vehicle.

Scheme 35

Scheme 36

Scheme 37

1. From inside vehicle, hold up accelerator pedal. Remove plastic cable retainer (clip) (7) and throttle cable core wire from upper end of pedal arm (6). Plastic cable retainer (clip) snaps into pedal arm.
2. Remove cable core wire at pedal arm.
3. From inside vehicle, remove cable clip (2) holding cable to dashpanel.
4. Remove air box at throttle body.
5. Unsnap cable from dashpanel routing clip.
6. Remove cable housing from dash panel and pull into engine compartment.
7. Using finger pressure only, disconnect accelerator cable connector at throttle body bellcrank pin by pushing connector off bellcrank pin towards front of vehicle (4). DO NOT try to pull connector off perpendicular to bellcrank pin. Connector will be broken.
8. Lift accelerator cable from top of cable cam (6).
9. Press tab (3) to release plastic cable mount from bracket. Press on tab only enough to release cable from bracket. If tab is pressed too much, it will be broken. Slide plastic mount (2) towards passenger side of vehicle to remove cable from bracket.
10. Remove throttle cable from vehicle.

Scheme 38

Scheme 39

Scheme 40

1. Slide accelerator cable plastic mount into throttle body mounting bracket. Continue sliding until; release tab (2) is aligned to hole in mounting bracket.
2. Hold throttle in wide open position. While held in this position, slide throttle cable pin (1) into throttle body bellcrank.
3. Push cable housing into rubber grommet and through opening in dash panel.
4. From inside vehicle, install metal clip (2) holding cable to dashpanel.
5. From inside vehicle, slide throttle cable core wire into opening (slot) in top of pedal arm.
6. Push plastic cable retainer (clip) (7) into pedal arm opening (6) until it snaps in place.
7. Install air resonator tube to throttle body.
8. Before starting engine, operate accelerator pedal to check for any binding.

Scheme 41

Scheme 42

1. Slide accelerator cable plastic mount into bracket. Continue sliding until tab (3) is aligned to hole in mounting bracket.
2. Route accelerator cable over top of cable cam.
3. Connect cable end to throttle body bellcrank pin (snaps on rearward).
4. Slide rubber grommet away from plastic cable housing.
5. Install rubber grommet into dash panel until seated.
6. Push cable housing into rubber grommet and through opening in dash panel.
7. From inside vehicle, install clip (2) holding cable to dashpanel.
8. From inside vehicle, slide throttle cable core wire into opening (6) in top of pedal arm.
9. Push cable retainer (clip) (7) into pedal arm opening (6) until it snaps in place.
10. Snap cable into dashpanel routing clip.
11. Install air resonator tube to throttle body.
12. Before starting engine, operate accelerator pedal to check for any binding.

3.7L V6

The Throttle Position Sensor (TPS) is mounted to the throttle body (1).

Scheme 43

1. Remove air resonator tube at throttle body.
2. Disconnect TPS electrical connector.
3. Remove two TPS mounting screws (2).
4. Remove TPS.

The TPS is located on the throttle body (2).

Scheme 44

1. Remove air duct and tube at throttle body.
2. Disconnect TPS electrical connector.
3. Remove two TPS mounting bolts (screws) (5).
4. Remove TPS from throttle body.

The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body.

The throttle shaft end of throttle body (3) slides into a socket in TPS (4). The TPS must be installed so that it can be rotated a few degrees. (If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs). The TPS will be under slight tension when rotated.

Scheme 45

1. Install TPS and retaining screws.
2. Tighten screws to 7 N.m (60 in. lbs.) torque.
3. Connect TPS electrical connector to TPS.
4. Manually operate throttle (by hand) to check for any TPS binding before starting engine.
5. Install air cleaner tube to throttle body.

The throttle shaft end of throttle body (5) slides into a socket in TPS (4). The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs. The TPS will be under slight tension when rotated.

Scheme 46

1. Install TPS and two retaining bolts.
2. Tighten bolts to 7 N.m (60 in. lbs.) torque.
3. Manually operate throttle control lever by hand to check for any binding of TPS.
4. Connect TPS electrical connector to TPS.
5. Install air duct/air box to throttle body.