Fuel Injection - Diesel Engine Dodge Pickup R1500

DESCRIPTION

Engine Mounted Sensor: The APPS assembly is located at the top-left-front of the engine. A plastic cover is used to cover the assembly. The actual sensor is located behind its mounting bracket.

Battery Tray Mounted Sensor: The Accelerator Pedal Position Sensor (APPS) assembly is located under the vehicle battery tray. A cable connects the assembly to the accelerator pedal. A plastic cover with a movable door is used to cover the assembly.

OPERATION

Engine Mounted Sensor: The Accelerator Pedal Position Sensor (APPS) is a linear potentiometer. It provides the Engine Control Module (ECM) with a DC voltage signal proportional to the angle, or position of the accelerator pedal.

Battery Tray Mounted Sensor: The APPS provides the ECM with two DC voltage signals which change as the position of the accelerator changes. One of the DC voltage signals will be half the voltage of the other signal.

Engine Mounted Sensor

The APPS is serviced (replaced) as one assembly including the lever, brackets and sensor. The APPS is calibrated to its mounting bracket. The APPS assembly is located at left-front of engine below plastic cable/lever/linkage cover (Scheme 182)

Scheme 182

Scheme 183

Scheme 184

Scheme 185

1. Disconnect both negative battery cables at both batteries.
2. Remove cable cover (Scheme 182) Cable cover is attached with 2 Phillips screws, 2 plastic retention clips and 2 push tabs (Scheme 182) Remove 2 Phillips screws and carefully pry out 2 retention clips. After clip removal, push rearward on front tab, and upward on lower tab for cover removal.
3. Using finger pressure only, disconnect end of speed control servo cable from throttle lever pin by pulling forward on connector while holding lever rearward (Scheme 183) DO NOT try to pull connector off perpendicular to lever pin. Connector will be broken.
4. Using two small screwdrivers, pry throttle cable connector socket from throttle lever ball (Scheme 183) Be very careful not to bend throttle lever arm.
5. Disconnect transmission control cable at lever arm (if equipped). Refer to «OVERHAUL - 48RE»(/dodge/pickup-r1500/1997-2012/remont/automatic-trans/#overhaul-48re-automatic-transmission).
6. Squeeze pinch tabs on speed control cable (Scheme 183) and pull cable rearward to remove from cable mounting bracket.
7. Squeeze pinch tabs on throttle cable (Scheme 183) and pull cable rearward to remove from cable mounting bracket.
8. Refer to «OVERHAUL - 48RE»(/dodge/pickup-r1500/1997-2012/remont/automatic-trans/#overhaul-48re-automatic-transmission) for transmission control cable removal procedures.
9. Disconnect wiring harness clip (Scheme 184) at bottom of bracket.
10. Remove 6 mounting bolts (Scheme 184) and partially remove APPS assembly from engine. After assembly is partially removed, disconnect electrical connector from bottom of sensor by pushing on connector tab (Scheme 185)
11. Remove APPS assembly from engine.

Battery Tray Mounted Sensor

The APPS is serviced (replaced) as one assembly including the sensor, plastic housing and cable. The APPS assembly is located under the left (drivers side) vehicle battery tray (Scheme 186) Access to APPS is gained from over top of left / front tire.

Scheme 186

Scheme 187

Scheme 188

1. Disconnect negative battery cable at battery.
2. Disconnect APPS cable at accelerator pedal. Refer to Accelerator Pedal «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-diesel-engine__removal) / «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-diesel-engine__installation).
3. Remove wheel house liner at left / front wheel. Refer to «FRONT WHEELHOUSE SPLASH SHIELD»(/dodge/pickup-r1500/1997-2012/remont/exterior-body-panels/#exterior).
4. Gain access to APPS electrical connector by opening swing-down door (Scheme 187) Disconnect electrical connector.
5. Remove 3 mounting bolts (Scheme 187)
6. Remove APPS assembly from battery tray.
7. If cable is to be separated at APPS, unsnap cable clip from ball socket (Scheme 188) Release cable from plastic housing by pressing on small cable release tab (Scheme 187)

The APPS is serviced (replaced) as one assembly including the lever, brackets and sensor. The APPS is calibrated to its mounting bracket.

1. Snap electrical connector into bottom of sensor.
2. Position APPS assembly to engine and install 6 bolts. Tighten bolts to 24 N.m (18 ft. lbs.) torque.
3. Connect wiring harness clip at bottom of bracket.
4. Refer to «OVERHAUL - 48RE»(/dodge/pickup-r1500/1997-2012/remont/automatic-trans/#overhaul-48re-automatic-transmission) for transmission control cable installation procedures.
5. Install speed control cable into mounting bracket. Be sure pinch tabs have secured cable.
6. Install throttle cable into mounting bracket. Be sure pinch tabs have secured cable.
7. Connect throttle cable at lever (snaps on).
8. Connect speed control cable to lever by pushing cable connector rearward onto lever pin while holding lever forward.
9. Install cable cover.
10. Connect both negative battery cables to both batteries.
11. If necessary, use DRB III(R) Scan Tool to erase any Diagnostic Trouble Codes (DTC's) from ECM.

1. Install Accelerator Pedal Position Sensor (APPS) cable to accelerator pedal. Refer to Accelerator Pedal «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-diesel-engine__removal) / «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-diesel-engine__installation) .
2. Connect electrical connector to APPS.
3. If necessary, connect cable to APPS lever ball socket (snaps on).
4. Snap APPS cable cover closed.
5. Position APPS assembly to bottom of battery tray and install 3 bolts. Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-diesel) .
6. Install wheelhouse liner. Refer to «FRONT WHEELHOUSE SPLASH SHIELD»(/dodge/pickup-r1500/1997-2012/remont/exterior-body-panels/#exterior) .
7. Perform the following procedure: Connect negative battery cables to both batteries. Turn key switch ON, but do not crank engine. Leave key switch ON for a minimum of 10 seconds. This will allow ECM to learn electrical parameters.
8. If necessary, use DRB III(R) Scan Tool to erase any Diagnostic Trouble Codes (DTC's) from ECM.

The Camshaft Position Sensor (CMP) on the 5.9L diesel engine is located below the fuel injection pump. It is bolted to the back of the timing gear housing.

The diesel Camshaft Position Sensor (CMP) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the camshaft gear. This hall effect device detects notches located on the back side of the camshaft gear. As the camshaft gear rotates, the notches pass the tip of the CMP.

When the leading edge of the notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts.

When the trailing edge of the notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts.

The CMP (Scheme 189) provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running.

Scheme 189

REMOVAL

The Camshaft Position Sensor (CMP) on the 5.9L diesel engine is located below the fuel injection pump. It is bolted to the back of the timing gear housing (Scheme 190)

Scheme 190

1. Disconnect electrical connector at CMP sensor (Scheme 190)
2. Remove sensor mounting bolt.
3. Carefully twist sensor from timing gear housing.
4. Check condition of sensor o-ring.

INSTALLATION

1. Clean out machined hole in back of timing gear housing (cover).
2. Apply a small amount of engine oil to sensor o-ring.
3. Install sensor into timing gear housing (cover) with a slight rocking action. Do not twist sensor into position as damage to o-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain housing (cover). If sensor is not flush, damage to sensor mounting tang may result.
4. Install mounting bolt and tighten. Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-diesel) .
5. Connect electrical connector to sensor.

The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper).

The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running (Scheme 191) The CKP contains a hall effect device. A rotating, notched target wheel (tone-wheel) for the CKP is located on the engine harmonic balancer (Scheme 192) This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP.

When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts.

When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts.

The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed.

Scheme 191

Scheme 192

Scheme 193

1. Raise and support vehicle
2. Disconnect electrical connector at CKP sensor (Scheme 193)
3. Remove 1 sensor mounting bolt.
4. Remove CKP sensor.

1. Position and install CKP sensor to engine.
2. Install 1 sensor mounting bolt and tighten to 9 N.m (80 in. lbs.) torque.
3. Install electrical connector to CKP sensor (Scheme 193)

The Fuel Control Actuator (FCA) is located at the rear of the high-pressure, fuel injection pump (Scheme 194)

Scheme 194

The Fuel Control Actuator (FCA) is an electronically controlled solenoid valve. The ECM controls the amount of fuel that enters the high-pressure pumping chambers by opening and closing the FCA based on a demanded fuel pressure. When the FCA is opened, the maximum amount of fuel is being supplied to the fuel injection pump. Any fuel that does not enter the injection pump is directed to the cascade overflow valve. The cascade overflow valve regulates how much excess fuel is used for lubrication of the pump and how much is returned to the fuel tank through the drain manifold.

An audible click from the FCA is normal when operating the key from the ON to the OFF position.

The Fuel Control Actuator (FCA) is a non-servicable part.

Six individual, solenoid actuated high-pressure fuel injectors are used (Scheme 195) The injectors are vertically mounted into a bored hole in the top of the cylinder head. This bored hole is located between the intake/exhaust valves. High-pressure connectors (Scheme 196), mounted into the side of the cylinder head, connect each fuel injector to each high-pressure fuel line.

Scheme 195

High-pressure fuel is supplied from the injection pump, through a high-pressure fuel line, into a fuel rail, through high-pressure lines, through steel connectors and into the solenoid actuated fuel injector. The ECM actuates the solenoid causing the needle valve to rise and fuel flows through the spray holes in the nozzle tip into the combustion chamber.

Each fuel injector is connected to the fuel rail by a high-pressure fuel line and a steel connector. This steel connector is positioned into the cylinder head and sealed with an o-ring. The connector is retained in the cylinder head by a nut (fitting) that is threaded into the cylinder head.

The torquing force of this threaded nut (fitting) provides a sealing pressure between the fuel line connector and the fuel injector. Retaining nut torque is very critical. If the nut (fitting) is under torqued, the mating surfaces will not seal and a high-pressure fuel leak will result. If the fitting is over torqued, the connector and injector will deform and also cause a high-pressure fuel leak. This leak will be inside the cylinder head and will not be visible. The result will be a possible fuel injector miss-fire and low power, or a no-start condition.

The fuel injectors use hole type nozzles. High-pressure flows into the side of the injector, the ECM activates the solenoid causing the injector needle to lift and fuel to be injected. The clearances in the nozzle bore are extremely small and any dirt or contaminants will cause the injector to stick. Because of this, it is very important to do a thorough cleaning of any lines before opening up any fuel system component. Always cover or cap any open fuel connections before a fuel system repair is performed.

Each fuel injector connector tube contains an edge filter that is designed to break up small contaminants before entering the fuel injector. The edge filters are not a substitute for proper cleaning and covering of all fuel system components during repair.

The bottom of each fuel injector is sealed to the cylinder head with a 1.5mm thick copper shim (gasket). The correct thickness shim must always be reinstalled after removing an injector.

Fuel pressure in the injector circuit decreases after injection. The injector needle valve is immediately closed and fuel flow into the combustion chamber is stopped. Exhaust gases are prevented from entering the injector nozzle by the needle valve.

Scheme 196

Six individual, solenoid actuated high-pressure fuel injectors are used (Scheme 195) The injectors are vertically mounted into a bored hole in the top of the cylinder head. This bored hole is located between the intake/exhaust valves. High-pressure connectors (Scheme 196), mounted into the side of the cylinder head, connect each fuel injector to each high-pressure fuel line.

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

1. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables.
2. Remove breather assembly.
3. Remove valve cover. Refer to «OVERHAUL - 5.9L DIESEL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul) for procedures.
4. Remove necessary high pressure fuel line connecting necessary fuel injector rail to high pressure connector. Refer to «FUEL LINES»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-diesel) for procedures.
5. A connector retainer (nut) (Scheme 196) is used on each connector tube. Remove this nut(s) by unthreading from cylinder head.
6. Using special high-pressure connector removal tool #9015 (Scheme 197), or (Scheme 198) remove necessary high-pressure connector(s) from cylinder head. Tool #9015 threads onto connector tube. Use tool to pry connector tube(s) from cylinder head.
7. Remove necessary exhaust rocker arm assembly(s).
8. Disconnect injector solenoid wire nuts at top of injectors (Scheme 199)
9. Remove 2 fuel injector hold-down clamp bolts at each injector being removed.
10. USING TOOL #9010: Special Tool #9010 (Scheme 200) is equipped with 2 clamshell clamps, a sliding retainer sleeve to retain the clamshell clamps, a 2-piece mounting stud, and a pivoting handle. Do not attempt to remove the fuel injector with any other device. Damage to injector will occur. The rocker housing (Scheme 199) is bolted to the top of cylinder head. The mounting stud from tool #9010 was meant to temporarily replace a rocker housing mounting bolt. Remove the necessary rocker housing mounting bolt. These mounting bolts are located at the center of each of the 3 rocker housing support bridges. Install and tighten 2-piece mounting stud to rocker housing. If removing the #6 fuel injector, separate the 2-piece mounting stud. Install lower half of mounting stud to center of rocker housing bridge. Install upper half of mounting stud to lower half. Position tool handle to mounting stud and install handle nut. Leave handle nut loose to allow a pivoting action. Position lower part of clamshell halves to sides of fuel injector (wider shoulder to bottom). The upper part of clamshell halves should also be positioned into machined shoulder on the handles pivoting head. Slide the retainer sleeve over pivoting handle head to lock clamshell halves together. Be sure handle pivot nut is loose. Depress handle downward to remove fuel injector straight up from cylinder head bore.
11. Remove and discard injector sealing washer. This should be located on tip of injector (Scheme 201) or (Scheme 202)

1. Inspect fuel injector: Look for burrs on injector inlet. Check nozzle holes for hole erosion or plugging. Inspect end of nozzle for burrs or rough machine marks. Look for cracks at nozzle end. If any of these conditions occur, replace injector.
2. Thoroughly clean fuel injector cylinder head bore. Blow out bore hole with compressed air.
3. The bottom of fuel injector is sealed to cylinder head bore with a copper sealing washer (shim) of a certain thickness (Scheme 201) A new shim with correct thickness must always be re-installed after removing injector. Measure thickness of injector shim (Scheme 202) Shim Thickness: 1.5 mm (.060")
4. Install new shim (washer) to bottom of injector. Apply light coating of clean engine oil to washer. This will keep washer in place during installation.
5. Install new o-ring to fuel injector. Apply small amount of clean engine oil to o-ring.
6. Install injector into cylinder head with male (high-pressure) connector port facing the intake manifold. Push down on fuel injector mounting flange to engage o-ring and seat injector.
7. Tightening Sequence: Install fuel injector holdown clamp (mounting flange) bolts. Do a preliminary tightening of these bolts to 5 N.m (44 in. lbs.) torque. This preliminary tightening insures the fuel injector is seated and centered. After tightening, relieve bolt torque, but leave both bolts threaded in place. Install high-pressure connector and retaining nut. Do a preliminary tightening to 15 N.m (11 ft. lbs.) torque. Alternately tighten injector holdown bolts to 10 N.m (89 in. lbs.) torque. Do a final tightening of the high-pressure connector and retaining nut. Tighten to 50 N.m (37 ft. lbs.) torque.
8. Connect injector solenoid wires and nuts to top of injectors (Scheme 199) Tighten connector nuts to 1.25 N.m (11 in. lbs.) torque. Be very careful not to overtighten these nuts as damage to fuel injector will occur.
9. Install exhaust rocker arm assembly. Refer to «OVERHAUL - 5.9L DIESEL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul).
10. Set exhaust valve lash. Refer to «OVERHAUL - 5.9L DIESEL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul).
11. Install high pressure fuel line. Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-diesel). Be sure to use a secondary back-up wrench on the connector nut (fitting) while torquing fuel line fitting. Refer to «FUEL LINES»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-diesel) for additional information.
12. Install valve cover. Refer to «OVERHAUL - 5.9L DIESEL»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#59l-engine-overhaul).
13. Install breather assembly.
14. Connect negative battery cables to both batteries.

The fuel injector rail is bolted to the top of the intake manifold.

The fuel rail is used as a distribution device to supply high-pressure fuel to the high-pressure fuel lines.

Scheme 203

1. Disconnect both negative battery cables at both batteries. Isolate ends of both cables.
2. Disconnect electrical connector at fuel pressure sensor.
3. Remove banjo bolt at fuel limiting valve.
4. Disconnect necessary wiring harness retention clips from intake manifold.
5. Lift 2 rubber covers to gain access to positive (+), intake heater cable nuts. Remove 2 nuts and remove 2 cables from studs.
6. Carefully remove 4 high-pressure fuel lines from top of injector rail engine. Note position of each line while removing. Do not bend lines while removing. CAUTION: WHEN LOOSENING OR TIGHTENING HIGH-PRESSURE LINES ATTACHED TO A SEPARATE FITTING, USE A BACK-UP WRENCH ON FITTING. DO NOT ALLOW FITTING TO ROTATE. DAMAGE TO BOTH FUEL LINE AND FITTING WILL RESULT.
7. Carefully remove 2 high-pressure fuel lines at each end of injector rail. Note position of each line while removing. Do not bend lines while removing.
8. Remove fuel line connecting injector pump to fuel rail.
9. Remove 3 injector rail mounting bolts (Scheme 203)
10. Remove rail from top of intake manifold.

1. Clean any dirt/debris from top of intake manifold and bottom of fuel rail.
2. Position fuel rail to top of manifold and install 3 mounting bolts. Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-diesel) .
3. Install all high-pressure lines to rail. Refer to «FUEL LINES»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-diesel) for procedures.
4. Reposition wiring harness to intake manifold and install new tie wraps.
5. Install and tighten fuel limiting valve banjo bolt. Refer to «SPECIFICATIONS»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-diesel) .
6. Connect electrical connector to fuel pressure sensor.
7. Position 2 positive (+) cables to intake heater studs. Install 2 nuts.
8. Connect battery cables to both batteries.
9. Start engine and check for leaks.

The combination, dual function Inlet Air Temperature/Pressure Sensor is located on the air cleaner (filter) cover.

The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor.

The Inlet Air Temperature/Pressure Sensor is located on the air cleaner cover (Scheme 204)

Scheme 204

Scheme 205

Scheme 206

1. Disconnect electrical connector at sensor (Scheme 205)
2. Remove two Torx-type mounting screws.
3. Remove sensor from air cleaner cover.
4. Check condition of sensor o-ring (Scheme 206)

1. Check condition of sensor o-ring.
2. Position sensor into top of air cleaner cover with a slight twisting action.
3. Install 2 mounting screws.
4. Install electrical connector.

The intake manifold air heater element assembly is located in the top of the intake manifold.

The air heater elements are used to heat incoming air to the intake manifold. This is done to help engine starting and improve driveability with cool or cold outside temperatures.

Electrical supply for the 2 air heater elements is controlled by the Engine Control Module (ECM) through the 2 air heater relays. Refer to INTAKE MANIFOLD AIR HEATER RELAYS for more information.

Two heavy-duty cables connect the 2 air heater elements to the 2 air heater relays. Each of these cables will supply approximately 95 amps at 12 volts to an individual heating element within the heater block assembly.

Refer to POWERTRAIN DIAGNOSTIC PROCEDURES (PART 1) and POWERTRAIN DIAGNOSTIC PROCEDURES (PART 2) for electrical operation and complete description of the intake heaters, including pre-heat and post-heat cycles.

If servicing either of the heater elements, the entire block/element assembly must be replaced.

Scheme 207

Scheme 208

Scheme 209

1. Disconnect both negative battery cables at both batteries. Cover and isolate ends of both cables.
2. Remove both the intake manifold air intake tube (above injection pump), and its rubber connector hose (Scheme 207)
3. Lift 2 rubber covers (Scheme 208) to gain access to 2 positive (+) cable nuts. Remove these 2 nuts (Scheme 209) and remove 2 cables from studs.
4. Disconnect ground strap (Scheme 208) at heater element stud.
5. Remove wiring harness clips.
6. Remove engine oil dipstick tube bracket from air inlet connection and fuel filter housing.
7. Remove 4 housing mounting bolts (Scheme 208) and remove heater element assembly.

If servicing either of the heater elements, the entire block/element assembly must be replaced.

1. Using 2 new gaskets, position element assembly and air housing to intake manifold.
2. Install ground cable to air housing.
3. Install 4 housing bolts and tighten to 24 N.m (18 ft. lbs.) torque.
4. Connect 2 positive (+) heater cables at cable mounting studs. Do not allow either of the cable eyelets to contact any other metal source other than the cable nuts/studs.
5. Install engine oil dipstick tube and mounting bolt.
6. Connect rubber connector hose and intake tube to air intake housing. Tighten clamp bolts to 11 N.m (95 in. lbs.) torque.
7. Connect both negative battery cables at both batteries.

The 2 intake manifold air heater relays are located in the engine compartment. They are attached to a common bracket. This bracket is attached to the right battery tray (Scheme 210)

Scheme 210

The Engine Control Module (ECM) operates the 2 heating elements through the 2 intake manifold air heater relays.

Refer to POWERTRAIN DIAGNOSTIC PROCEDURES (PART 1) and POWERTRAIN DIAGNOSTIC PROCEDURES (PART 2) for an electrical operation and complete description of the intake heaters, including pre-heat and post-heat cycles.

The 2 intake manifold air heater relays are located in the engine compartment. They are attached to a common bracket. This bracket is attached to the right battery tray (Scheme 210)

The mounting bracket and both relays are replaced as an assembly.

1. Disconnect both negative battery cables at both batteries.
2. Disconnect four relay trigger wires at both relays. Note position of wiring before removing.
3. Lift four rubber shields from all 4 cables.
4. Remove four nuts at cable connectors. Note position of wiring before removing.
5. Remove relay mounting bracket bolts and remove relay assembly.

1. Install relay assembly to battery tray. Tighten mounting bolts to 4.5 N.m (40 in. lbs.) torque.
2. Connect eight electrical connectors to relays.
3. Connect battery cables to both batteries.

The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold.

The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream.

The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure.

The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) sensor is installed into the top of the intake manifold (Scheme 211)

1. Clean area around sensor.
2. Disconnect electrical connector from IAT/MAP sensor.
3. Remove two T-15 Torx headed screws.
4. Remove sensor from intake manifold.
5. Check condition of sensor o-ring (Scheme 212)

1. Check condition of sensor o-ring.
2. Lubricate sensor o-ring with clean engine oil.
3. Clean sensor mounting area at intake manifold.
4. Position sensor into intake manifold.
5. Install and tighten 2 sensor mounting screws to 1 N.m (9 in. lbs.) torque.
6. Connect electrical connector to sensor.

A combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is used. Refer to INTAKE AIR TEMPERATURE SENSOR/MAP SENSOR for information.

Scheme 211

Scheme 212

If Equipped With Engine Mounted Accelerator Pedal Position Sensor

Scheme 213

Scheme 214

Scheme 215

1. Disconnect both negative battery cables at both batteries.
2. From inside vehicle, hold up accelerator pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Scheme 213) The plastic cable retainer snaps into pedal arm.
3. From inside vehicle, remove cable clip (Scheme 213)
4. Remove cable core wire at pedal arm.
5. Remove cable housing from dash panel and pull cable into engine compartment.
6. Remove cable cover (Scheme 214) Cable cover is attached with 2 Phillips screws, 2 plastic retention clips and 2 push tabs (Scheme 214) Remove 2 Phillips screws and carefully pry out 2 retention clips. After clip removal, push rearward on front tab, and upward on lower tab for cover removal.
7. Using 2 screwdrivers, pry cable connector socket from throttle lever ball (Scheme 215) Be very careful not to bend throttle lever arm.

If Equipped With Battery Tray Mounted Accelerator Pedal Position Sensor

The Throttle Control Cable connects the accelerator pedal to the Accelerator Pedal Position Sensor (APPS). A separate mechanical cable is not routed to the throttle body.

Scheme 216

1. Disconnect both negative battery cables at both batteries.
2. From inside vehicle, hold up accelerator pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Scheme 216) The plastic cable retainer snaps into pedal arm.
3. Remove cable core wire at pedal arm.
4. Remove APPS. Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-diesel-engine__removal) / «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-diesel-engine__installation).
5. From inside vehicle, remove cable clip (Scheme 216)
6. Remove cable housing from dash panel and pull cable into engine compartment.
7. Remove cable housing at APPS bracket by pressing on release tab with a small screwdriver. To prevent cable housing breakage, press on tab only enough to release cable from APPS bracket.

Accelerator Pedal Position Sensor Mounted To Engine

1. Install cable through mounting hole on cable mounting bracket (Scheme 215) Cable snaps into bracket. Be sure 2 pinch tabs are secure.
2. Using large pliers, connect cable end socket to throttle lever ball (snaps on).
3. Install remaining cable housing end into and through dash panel opening (snaps into position). The two plastic pinch tabs should lock cable to dash panel.
4. From inside vehicle, hold up accelerator pedal. Install throttle cable core wire and plastic cable retainer into and through upper end of pedal arm (the plastic retainer is snapped into pedal arm). When installing plastic retainer to accelerator pedal arm, note index tab on pedal arm (Scheme 213) Align index slot on plastic cable retainer to this index tab.
5. Connect negative battery cables to both batteries.
6. Before starting engine, operate accelerator pedal to check for any binding.
7. Install cable/lever cover.

Accelerator Pedal Position Sensor Not Mounted To Engine

1. Attach cable to Accelerator Pedal Position Sensor (APPS). Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-diesel-engine__removal) / «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-diesel-engine__installation).
2. Push cable housing into rubber grommet and through opening in dash panel.
3. From inside vehicle, install clip holding cable to dashpanel (Scheme 216)
4. From inside vehicle, slide throttle cable core wire into opening in top of pedal arm.
5. Push cable retainer (clip) into pedal arm opening until it snaps in place.
6. Before starting engine, operate accelerator pedal to check for any binding.
7. If necessary, use DRB III(R) Scan Tool to erase any APPS Diagnostic Trouble Codes (DTC's) from Engine Control Module (ECM).

This Engine Control Module (ECM) input is used only on models equipped with aftermarket Power Take Off (PTO) units.

This input is used only to tell the ECM that the aftermarket PTO (Power Take Off) unit has been engaged. The ECM will disable (temporarily shut down) certain OBD II diagnostic trouble codes when the PTO unit is engaged.

See also:
• OVERHAUL - 48RE
• FRONT WHEELHOUSE SPLASH SHIELD
• SPECIFICATIONS
• OVERHAUL - 5.9L DIESEL
• POWERTRAIN DIAGNOSTIC PROCEDURES (PART 1)
• POWERTRAIN DIAGNOSTIC PROCEDURES (PART 2)
• REMOVAL
• INSTALLATION
• CLEANING FUEL SYSTEM PARTS