Fuel Injection - Gas Engine Dodge Pickup R1500

REMOVAL

The following procedure applies only to vehicles without the Adjustable Pedal Package (code XAP).

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) (Scheme 52) This plastic retainer snaps into the top of the accelerator pedal arm.

1. From inside the vehicle, hold up accelerator pedal. Remove plastic cable retainer (clip) and throttle cable core wire from upper end of accelerator pedal arm (Scheme 52) Plastic cable retainer (clip) snaps into pedal arm.
2. Remove 2 accelerator pedal mounting bracket nuts. Remove accelerator pedal assembly.

INSTALLATION

1. Place accelerator pedal assembly over 2 studs.
2. Install and tighten 2 mounting nuts to 105 in. lbs. (12 N.m). .
3. Slide throttle cable into opening slot in top of pedal arm.
4. Push plastic cable retainer (clip) into accelerator pedal arm opening until it snaps into place.
5. Before starting engine, operate accelerator pedal to check for any binding.

DESCRIPTION

The Accelerator Pedal Position Sensor (APPS) assembly is located under the vehicle battery tray. A cable connects the assembly to the accelerator pedal.

Scheme 52

A plastic cover with a movable door is used to cover the assembly.

The APPS is used only with the 5.7L V-8 engine.

OPERATION

The Accelerator Pedal Position Sensor (APPS) is a linear potentiometer. It provides the Powertrain Control Module (PCM) with a DC voltage signal proportional to the angle, or position of the accelerator pedal. The APPS signal is translated (along with other sensors) to place the throttle plate (within the throttle body) to a pre-determined position.

A mechanical cable is used between the accelerator pedal and the APPS assembly. Although a cable is used between the pedal and APPS, a mechanical cable is not used at the throttle body. Throttle plate position is electrically determined.

The APPS is serviced (replaced) as one assembly including the sensor, plastic housing and cable. The APPS assembly is located under the vehicle battery tray (Scheme 53) Access to APPS is gained from over top of left/front tire.

Scheme 53

Scheme 54

Scheme 55

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-gas-engine__removal).
3. Remove wheel house liner at left/front wheel.
4. Gain access to APPS electrical connector by opening swing-down door (Scheme 54) Disconnect electrical connector.
5. Remove 3 mounting bolts (Scheme 54)
6. Remove APPS assembly from battery tray.
7. If cable is to be separated at APPS, unsnap cable clip from ball socket (Scheme 55) Release cable from plastic housing by pressing on small cable release tab (Scheme 54)

1. Install Accelerator Pedal Position Sensor (APPS) cable to accelerator pedal. Refer to Accelerator Pedal «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-gas-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. Tight bolts to 30 in. lbs. (3 N.m).
6. Install wheelhouse liner.
7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: Connect negative battery cable to battery. Turn ignition switch ON, but do not crank engine. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. The DRB III® Scan Tool may also 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 DRB III® Scan Tool to erase any Diagnostic Trouble Codes (DTC's) from PCM.

3.7L V-6

The Crankshaft Position (CKP) (Scheme 56) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole.

4.7L V-8

The Crankshaft Position (CKP) (Scheme 57) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole.

Scheme 56

Scheme 57

5.7L V-8

The Crankshaft Position (CKP) (Scheme 58) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole.

Scheme 58

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 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 (Scheme 59) This tonewheel has sets of notches at its outer edge (Scheme 59)

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

Scheme 59

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

A tonewheel is bolted to the engine crankshaft (Scheme 60) This tonewheel has sets of notches at its outer edge (Scheme 60)

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

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.

Scheme 60

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

A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches at its outer edge (Scheme 61)

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

The Crankshaft Position (CKP) sensor is mounted into the right rear side of the cylinder block (Scheme 62) It is positioned and bolted into a machined hole.

Scheme 61

Scheme 62

1. Raise vehicle.
2. Disconnect sensor electrical connector.
3. Remove sensor mounting bolt (Scheme 62)
4. Carefully twist sensor from cylinder block.
5. Check condition of sensor O-ring.

The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block (Scheme 63) It is positioned and bolted into a machined hole in the engine block.

Scheme 63

1. Raise vehicle.
2. Disconnect CKP electrical connector at sensor.
3. Remove CKP mounting bolt (Scheme 63)
4. Carefully twist sensor from cylinder block.
5. Remove sensor from vehicle.
6. Check condition of sensor O-ring.

The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine cylinder block (Scheme 64) It is positioned and bolted into a machined hole in the engine block.

Scheme 64

1. Raise vehicle.
2. Disconnect CKP electrical connector at sensor (Scheme 64)
3. Remove CKP mounting bolt (Scheme 64)
4. Carefully twist sensor from cylinder block.
5. Remove sensor from vehicle.
6. Check condition of sensor O-ring.

8.3L - SRT-10

The sensor is located at the rear lower passenger side of motor (Scheme 65)

Scheme 65

Scheme 66

1. Disconnect electrical connector from crankshaft position sensor (Scheme 66)
2. Remove sensor mounting bolt.
3. Pull sensor out. A light tap to top of sensor may ease removal.

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 (Scheme 67) 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.

Scheme 67

Scheme 68

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 (Scheme 68) 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.

Scheme 69

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 (Scheme 69) 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. Slide the sensor into the hole.
2. Install and tighten the mounting bolt to 11 N.m (95 in. lbs.) torque.
3. Connect the electrical connector to the sensor and lock.

An individual fuel injector (Scheme 70) is used for each individual cylinder.

Scheme 70

FUEL INJECTOR

The top (fuel entry) end of the injector (Scheme 71) is attached into an opening on the fuel rail.

Scheme 71

The fuel injectors are electrical solenoids. The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a pencil stream. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber.

The nozzle (outlet) ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector.

The injectors are energized individually in a sequential order by the Powertrain Control Module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives.

Battery voltage is supplied to the injectors through the ASD relay.

The PCM determines injector pulse width based on various inputs.

PCM OUTPUT

The nozzle ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector with its respective cylinder number.

The injectors are energized individually in a sequential order by the Powertrain Control Module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives.

Battery voltage (12 volts +) is supplied to the injectors through the ASD relay. The ASD relay will shutdown the 12 volt power source to the fuel injectors if the PCM senses the ignition is on, but the engine is not running. This occurs after the engine has not been running for approximately 1.8 seconds.

The PCM determines injector on-time (pulse width) based on various inputs.

3.7L, 4.7L, 5.7L

1. Remove fuel rail. (Refer to «FUEL RAIL»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine) ).
2. Disconnect clip(s) that retain fuel injector(s) to fuel rail (Scheme 72)

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

1. Release fuel system pressure. Refer to «STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine__standard-procedure-fuel-system-pressure).
2. Remove the battery cover and disconnect negative battery cable.
3. Remove the air cleaner assembly. Refer to the «AIR CLEANER HOUSING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) for more information.
4. Disconnect the electrical connector to the MAP sensor and Coolant Temperature sensor (Scheme 73)
5. Disconnect the electrical connector to the TPS and Idle Air Control (Scheme 74)
6. Remove the wiring harness from the wiring clips under thew throttle body (Scheme 75)
7. Disconnect the electrical connector from the fuel injectors (Scheme 76)
8. Disconnect the fuel line quick connector (Scheme 77)
9. Remove the bolts for the fuel rail (Scheme 78)
10. Pull fuel rail and injectors straight up and out of the intake manifold.
11. Move the fuel rail forward and out from under the intake manifold and throttle body (Scheme 79)
12. Remove the fuel injector from the fuel rail (Scheme 80)

Scheme 80

1. Install fuel injector(s) into fuel rail assembly and install retaining clip(s).
2. If same injector(s) is being reinstalled, install new o-ring(s).
3. Apply a small amount of clean engine oil to each injector o-ring. This will aid in installation.
4. Install fuel rail. (Refer to «FUEL RAIL»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine) ).
5. Start engine and check for fuel leaks.

1. Install the fuel injectors to the fuel rail.
2. Install fuel rail under throttle body.
3. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
4. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 12 N.m (105 in. lbs.) (Scheme 78)
5. Attach electrical connectors to fuel injectors (Scheme 76)
6. Connect the electrical connector to the MAP sensor and Coolant Temperature sensor (Scheme 73)
7. Connect the electrical connector to the TPS and Idle Air Control (Scheme 74)
8. Install the wiring harness to the wiring clips under the throttle body (Scheme 75)
9. Connect fuel supply tube to fuel rail (Scheme 76) Refer to «QUICK CONNECT FITTING»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-delivery-gas-engine).
10. Install the negative battery cable and install the battery cover.
11. Install the air cleaner assembly. Refer to the «AIR CLEANER HOUSING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) for more information.
12. Use the DRBIII® scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.

The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location.

The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM.

Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shutdown the ground circuit to the fuel pump relay in approximately 1-3 seconds unless the engine is operating or the starter motor is engaged.

The fuel pump relay is located in the Power Distribution Center (PDC) (Scheme 81) Refer to label on PDC cover for relay location.

1. Remove PDC cover.
2. Remove relay from PDC.
3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay.
4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay.

The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location.

1. Install relay to PDC.
2. Install cover to PDC.

The IAC stepper motor is mounted to the throttle body of the 3.7L (Scheme 82) and 4.7L (Scheme 83) engines, and regulates the amount of air bypassing the control of the throttle plate. As engine loads and ambient temperatures change, engine RPM changes. A pintle on the IAC stepper motor protrudes into a passage in the throttle body, controlling air flow through the passage. The IAC is controlled by the Powertrain Control Module (PCM) to maintain the target engine idle speed.

Scheme 81

A separate IAC motor is not used with the 5.7L V-8 engine.

Scheme 82

The idle air control motor is mounted at the front right of the intake manifold (Scheme 84)

Scheme 83

3.7L V-6/4.7L V-8

A separate IAC motor is not used with the 5.7L V-8 engine.

At idle, engine speed can be increased by retracting the IAC motor pintle and allowing more air to pass through the port, or it can be decreased by restricting the passage with the pintle and diminishing the amount of air bypassing the throttle plate.

The IAC is called a stepper motor because it is moved (rotated) in steps, or increments. Opening the IAC opens an air passage around the throttle blade which increases RPM.

The PCM uses the IAC motor to control idle speed (along with timing) and to reach a desired MAP during decel (keep engine from stalling).

The IAC motor has 4 wires with 4 circuits. Two of the wires are for 12 volts and ground to supply electrical current to the motor windings to operate the stepper motor in one direction. The other 2 wires are also for 12 volts and ground to supply electrical current to operate the stepper motor in the opposite direction.

Scheme 84

To make the IAC go in the opposite direction, the PCM just reverses polarity on both windings. If only 1 wire is open, the IAC can only be moved 1 step (increment) in either direction. To keep the IAC motor in position when no movement is needed, the PCM will energize both windings at the same time. This locks the IAC motor in place.

In the IAC motor system, the PCM will count every step that the motor is moved. This allows the PCM to determine the motor pintle position. If the memory is cleared, the PCM no longer knows the position of the pintle. So at the first key ON, the PCM drives the IAC motor closed, regardless of where it was before. This zeros the counter. From this point the PCM will back out the IAC motor and keep track of its position again.

When engine RPM is above idle speed, the IAC is used for the following

1. Off-idle dashpot (throttle blade will close quickly but idle speed will not stop quickly)
2. Deceleration air flow control
3. A/C compressor load control (also opens the passage slightly before the compressor is engaged so that the engine RPM does not dip down when the compressor engages)
4. Power steering load control

The PCM can control polarity of the circuit to control direction of the stepper motor.

IAC Stepper Motor Program: The PCM is also equipped with a memory program that records the number of steps the IAC stepper motor most recently advanced to during a certain set of parameters. For example: The PCM was attempting to maintain a 1000 RPM target during a cold start-up cycle. The last recorded number of steps for that may have been 125. That value would be recorded in the memory cell so that the next time the PCM recognizes the identical conditions, the PCM recalls that 125 steps were required to maintain the target. This program allows for greater customer satisfaction due to greater control of engine idle.

Another function of the memory program, which occurs when the power steering switch (if equipped), or the A/C request circuit, requires that the IAC stepper motor control engine RPM, is the recording of the last targeted steps into the memory cell. The PCM can anticipate A/C compressor loads. This is accomplished by delaying compressor operation for approximately 0.5 seconds until the PCM moves the IAC stepper motor to the recorded steps that were loaded into the memory cell. Using this program helps eliminate idle-quality changes as loads change. Finally, the PCM incorporates a "No-Load" engine speed limiter of approximately 1800 - 2000 RPM, when it recognizes that the TPS is indicating an idle signal and IAC motor cannot maintain engine idle.

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 IAC motor through the PCM.

The Idle Air Control (IAC) motor is located on the side of the throttle body (Scheme 54)

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 is located on the side of the throttle body (Scheme 86)

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.

Scheme 85

Scheme 86

The IAC motor is inserted into a housing at the front of the intake manifold (Scheme 84) The IAC motor and housing are serviced together.

1. Remove housing to manifold screws. Remove IAC motor and housing.
2. Disconnect the electrical connector from IAC motor.

The Idle Air Control (IAC) motor is located on the side of the throttle body (Scheme 87)

Scheme 87

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 Idle Air Control (IAC) motor is located on the side of the throttle body (Scheme 88)

Scheme 88

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 inserted into a housing at the front of the intake manifold (Scheme 84) The IAC motor and housing are serviced together.

1. Attach electrical connector to IAC motor.
2. Install IAC motor into and housing on manifold. Tighten mounting screws to 4 N.m (35 in. lbs.) torque.

Note. Take care not to damage the thermistor pill when removing the sensor.

Scheme 89

1. Remove the battery cover and disconnect the negative battery cable.
2. Disconnect the electrical connector from the inlet temperature sensor (Scheme 89)
3. Remove sensor from inlet hose.

Note. Take care not to damage the open thermistor pill when installing the sensor.

Scheme 90

1. Install sensor (Scheme 90), use a little water to aid in insertion of sensor.
2. Make sure that the rib on the sensor matches up with the rib on the inlet hose. The thermistor pill should be in direct contact with the inlet air stream.
3. Connect the electrical connector.
4. Connect the negative battery cable and install battery cover.

The 2-wire Intake Manifold Air Temperature (IAT) sensor (Scheme 91) is installed in the intake manifold with the sensor element extending into the air stream.

The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases.

Scheme 91

The 2-wire Intake Manifold Air Temperature (IAT) sensor (Scheme 92) is installed in the intake manifold with the sensor element extending into the air stream.

The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases.

Scheme 92

The 2-wire Intake Manifold Air Temperature (IAT) sensor (Scheme 93) is installed in the intake manifold with the sensor element extending into the air stream.

The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases.

The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit.

The PCM uses this input to calculate the following

1. Injector pulse-width
2. Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures)

The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor.

Scheme 93

The intake manifold air temperature (IAT) sensor is installed into the left side of intake manifold plenum (Scheme 94)

Scheme 94

Scheme 95

1. Disconnect electrical connector from IAT sensor.
2. Clean dirt from intake manifold at sensor base.
3. Gently lift on small plastic release tab ( (Scheme 94) or (Scheme 95) ) and rotate sensor about 1/4 turn counterclockwise for removal.
4. Check condition of sensor o-ring.

The intake manifold air temperature (IAT) sensor is installed into the left side of intake manifold plenum (Scheme 97)

Scheme 96

Scheme 97

1. Disconnect electrical connector from IAT sensor.
2. Clean dirt from intake manifold at sensor base.
3. Gently lift on small plastic release tab ( (Scheme 96) or (Scheme 97) ) and rotate sensor about 1/4 turn counterclockwise 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 (Scheme 98)

Scheme 98

Scheme 99

Scheme 100

1. Disconnect electrical connector from IAT sensor (Scheme 98)
2. Clean dirt from intake manifold at sensor base.
3. Gently lift on small plastic release tab ( (Scheme 99) or (Scheme 100) ) and rotate sensor about 1/4 turn counterclockwise for removal.
4. Check condition of sensor O-ring.

The intake manifold air temperature (IAT) sensor is installed into the left side of intake manifold plenum (Scheme 101)

Scheme 101

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 (Scheme 101)
4. Install electrical connector.

The intake manifold air temperature (IAT) sensor is installed into the left side of intake manifold plenum (Scheme 102)

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 intake manifold air temperature (IAT) sensor is installed into the front of the intake manifold air box plenum (Scheme 103)

Scheme 102

Scheme 103

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 (Scheme 104) is mounted into the front of the intake manifold with 2 screws.

Scheme 104

The Manifold Absolute Pressure (MAP) sensor (Scheme 105) is mounted into the front of the intake manifold with 2 screws.

Scheme 105

The Manifold Absolute Pressure (MAP) sensor (Scheme 106) is mounted to the front of the intake manifold air plenum box.

Scheme 106

The MAP sensor (Scheme 107) mounts to the drivers side intake manifold plenum.

Scheme 107

The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum.

A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM.

The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum.

During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor.

As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively.

The PCM uses the MAP sensor input to aid in calculating the following

1. Manifold pressure
2. Barometric pressure
3. Engine load
4. Injector pulse-width
5. Spark-advance programs
6. Shift-point strategies (certain automatic transmissions only)
7. Idle speed
8. Decel fuel shutoff

The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation.

The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area.

The Manifold Absolute Pressure (MAP) sensor is mounted into the front of the intake manifold (Scheme 108) An O-ring is used to seal the sensor to the intake manifold (Scheme 109)

Scheme 108

1. Disconnect electrical connector at sensor.
2. Clean area around MAP sensor.
3. Remove 2 sensor mounting screws.
4. Remove MAP sensor from intake manifold.
5. Check condition of sensor O-ring (Scheme 109)

The MAP sensor is located on the front of the intake manifold (Scheme 110) An o-ring seals the sensor to the intake manifold.

Scheme 109

Scheme 110

1. Disconnect electrical connector at sensor.
2. Clean area around MAP sensor.
3. Remove 2 sensor mounting bolts (Scheme 110)
4. Remove MAP sensor from intake manifold.
5. Check condition of sensor O-ring (Scheme 109)

The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box (Scheme 111)

Scheme 111

1. Disconnect electrical connector at sensor by sliding release lock out (Scheme 112) Press down on lock tab for removal.
2. Rotate sensor 1/4 turn counterclockwise for removal.
3. Check condition of sensor O-ring.

The manifold absolute pressure sensor is mounted on the drivers side of the intake manifold (Scheme 107)

1. Disconnect the electrical connector from the MAP sensor.
2. Remove MAP sensor mounting screws.

The Manifold Absolute Pressure (MAP) sensor is mounted into the front of the intake manifold (Scheme 113)

Scheme 112

Scheme 113

An O-ring is used to seal the sensor to the intake manifold (Scheme 114)

Scheme 114

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). Tighten to 30 in. lbs. (3 N.m).
5. Connect electrical connector.

The MAP sensor is located on the front of the intake manifold (Scheme 115)

An O-ring seals the sensor to the intake manifold (Scheme 116)

Scheme 115

Scheme 116

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). Tighten to 30 in. lbs. (3 N.m).
5. Connect electrical connector.

The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box (Scheme 117)

Scheme 117

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.

1. Install the MAP sensor to the intake manifold.
2. Install MAP sensor mounting screws and tighten mounting screws to 4 N.m (35 in. lbs.).
3. Connect the electrical connector to the MAP sensor.

The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors.

Federal Emission Packages : Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic converter. The downstream sensor (1/2) is located just after the main catalytic convertor.

California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor.

(Scheme 118)or (Scheme 119) for typical O2S (oxygen sensor) locations.

Scheme 118

Scheme 119

1. Raise and supports vehicle.
2. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor.
3. Remove O2S sensor with an oxygen sensor removal and installation tool.
4. Clean threads in exhaust pipe using appropriate tap.

Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor.

1. Install O2S sensor. Tighten to 30 N.m (22 ft. lbs.) torque.
2. Connect O2S sensor wire connector.
3. Lower vehicle.

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

The input is used only to tell the PCM (or ECM-Diesel) that the PTO has been engaged. The PCM (or ECM) will disable (temporarily shut down) certain OBD II diagnostic trouble codes when the PTO is engaged.

JTEC and NGC Engine Controllers: When the aftermarket PTO switch has been engaged, a 12V + signal is sent through circuit G113 to PCM pin A13. The PCM will then sense and determine that the PTO has been activated.

CM 845 or CM 848 Diesel Engine Controllers: When the aftermarket PTO switch has been engaged, a 12V + signal is sent through circuit G113 to ECM pin B38. The ECM will then sense and determine that the PTO has been activated.

The throttle body is located on the intake manifold. Fuel does not enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel injectors.

Filtered air from the air cleaner enters the intake manifold through the throttle body. The throttle body contains an air control passage controlled by an Idle Air Control (IAC) motor. The air control passage is used to supply air for idle conditions. A throttle valve (plate) is used to supply air for above idle conditions.

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 120

Scheme 121

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 the «ACCELERATOR PEDAL»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-gas-engine) for removal/installation procedures.
4. Disconnect necessary vacuum lines at throttle body.
5. Remove 3 throttle body mounting bolts (Scheme 120)
6. Remove throttle body from intake manifold.
7. Check condition of old throttle body-to-intake manifold O-ring (Scheme 121)

Scheme 122

1. Remove air duct and air resonator box at throttle body.
2. Disconnect throttle body electrical connectors at IAC motor and TPS (Scheme 122)
3. Remove vacuum line at throttle body.
4. Remove all control cables from throttle body (lever) arm. Refer to «ACCELERATOR PEDAL»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-gas-engine).
5. Remove three throttle body mounting bolts (Scheme 122)
6. Remove throttle body from intake manifold.

Scheme 123

Scheme 124

1. Remove air duct and air resonator box at throttle body.
2. Disconnect electrical connector at throttle body (Scheme 123)
3. Remove 4 throttle body mounting bolts (Scheme 123)
4. Remove throttle body from intake manifold.
5. Check condition of throttle body o-ring (Scheme 124)
6. If the throttle body has been changed, the following procedure must be performed: Disconnect negative battery cable from battery. Leave cable disconnected for approximately 90 seconds. Reconnect cable to battery. Turn ignition switch ON, but do not crank engine. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn throttle body electrical parameters.

Scheme 125

Scheme 126

Scheme 127

Scheme 128

1. Remove the battery cover and disconnect the negative battery cable.
2. Remove the air cleaner assembly. Refer to the «AIR CLEANER HOUSING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10) for more information.
3. Remove the throttle cable (Scheme 125)
4. Disconnect the TPS electrical connector (Scheme 126)
5. Remove the throttle body bolts (Scheme 127) and wiring clips (Scheme 128)
6. Remove the throttle body.

Scheme 129

1. Check condition of throttle body-to-intake manifold O-ring (Scheme 129) 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 (Scheme 130) 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.

Scheme 130

Scheme 131

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 (Scheme 131) 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.

Scheme 132

Scheme 133

1. Clean and check condition of throttle body-to-intake manifold o-ring (Scheme 132)
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 (Scheme 133) Tighten bolts to 105 in. lbs. (12 N.m).
5. Install electrical connector.
6. Install air plenum.
7. If the throttle body has been changed, the following procedure must be performed: Disconnect negative battery cable from battery. Leave cable disconnected for approximately 90 seconds. Reconnect cable to battery. Turn ignition switch ON, but do not crank engine. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn throttle body electrical parameters.

1. Mount throttle body (Scheme 127) and wiring clips (Scheme 128), tighten bolts to 12 N.m (105 in. lbs.).
2. Connect electrical connector to throttle position sensor (Scheme 126)
3. Install the throttle cable (Scheme 125)
4. Install the air cleaner housing. Refer to «AIR CLEANER HOUSING»(/dodge/pickup-r1500/1997-2012/remont/mechanical/#83l-engine-overhaul-srt-10).
5. Connect the negative battery cable and install the battery cover.

Scheme 134

1. From inside vehicle, hold up accelerator pedal. Remove plastic cable retainer (clip) and throttle cable core wire from upper end of pedal arm (Scheme 52) Plastic cable retainer snaps into top of pedal arm.
2. Remove cable core wire at pedal arm.
3. From inside vehicle, remove metal clip holding cable to dash panel (Scheme 52)
4. Remove air resonator box at throttle body.
5. Unsnap cable from dash panel 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 (Scheme 134) from throttle body bellcrank.
8. Using a pick or small screwdriver, press release tab (Scheme 135) 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 (Scheme 135) towards right side of vehicle to remove throttle cable from throttle body bracket.
9. Remove throttle cable from vehicle.

Scheme 135

1. From inside vehicle, hold up accelerator pedal. Remove plastic cable retainer (clip) and throttle cable core wire from upper end of pedal arm (Scheme 52) Plastic cable retainer (clip) snaps into pedal arm.
2. Remove cable core wire at pedal arm.
3. From inside vehicle, remove cable clip holding cable to dash panel (Scheme 52)
4. Remove air box at throttle body.
5. Unsnap cable from dash panel 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 (Scheme 136) DO NOT try to pull connector off perpendicular to bellcrank pin. Connector will be broken.
8. Lift accelerator cable from top of cable cam (Scheme 136)
9. Press tab (Scheme 137) 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 (Scheme 137) towards passenger side of vehicle to remove cable from bracket.
10. Remove throttle cable from vehicle.

The Throttle Control Cable on the 5.7L V-8 engine connects the accelerator pedal to the Accelerator Pedal Position Sensor (APPS). A separate mechanical cable is not routed to the throttle body.

Scheme 136

1. From inside vehicle, hold up accelerator pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Scheme 52) The plastic cable retainer snaps into pedal arm.
2. Remove cable core wire at pedal arm.
3. Remove APPS. Refer to «REMOVAL»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-gas-engine).
4. From inside vehicle, remove cable clip (Scheme 52)
5. Remove cable housing from dash panel and pull cable into engine compartment.
6. 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.

Scheme 137

1. Slide accelerator cable plastic mount into throttle body mounting bracket. Continue sliding until release tab (Scheme 135) is aligned to hole in mounting bracket.
2. Hold throttle in wide open position. While held in this position, slide throttle cable pin (Scheme 134) into throttle body bellcrank.
3. Push cable housing into rubber grommet and through opening in dash panel.
4. From inside vehicle, install metal clip holding cable to dash panel (Scheme 52)
5. From inside vehicle, slide throttle cable core wire into opening (slot) in top of pedal arm.
6. Push plastic cable retainer (clip) into pedal arm opening 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.

1. Slide accelerator cable plastic mount into bracket. Continue sliding until tab (Scheme 137) 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 holding cable to dash panel (Scheme 52)
8. From inside vehicle, slide throttle cable core wire into opening in top of pedal arm.
9. Push cable retainer (clip) into pedal arm opening until it snaps in place.
10. Snap cable into dash panel routing clip.
11. Install air resonator tube to throttle body.
12. Before starting engine, operate accelerator pedal to check for any binding.

1. Attach cable to Accelerator Pedal Position Sensor (APPS). Refer to «INSTALLATION»(/dodge/pickup-r1500/1997-2012/remont/fuel-system/#fuel-injection-gas-engine).
2. Push cable housing into rubber grommet and through opening in dash panel.
3. From inside vehicle, install clip holding cable to dash panel (Scheme 52)
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® Scan Tool to erase any APPS Diagnostic Trouble Codes (DTC's) from PCM.

The 3-wire Throttle Position Sensor (TPS) (Scheme 138) is mounted on the throttle body and is connected to the throttle blade shaft.

The 5.7L V-8 engine does not use a separate TPS on the throttle body.

The TPS is mounted on the passenger side of the throttle body. The sensor connects to the throttle blade shaft (Scheme 139) The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage).

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

The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes.

The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from .26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing.

Scheme 138

Scheme 139

The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations

1. Ignition timing advance
2. Fuel injection pulse-width
3. Idle (learned value or minimum TPS)
4. Off-idle (0.06 volt)
5. Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage)
6. Deceleration fuel lean out
7. Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage)
8. A/C WOT cutoff (certain automatic transmissions only)

3.7L V6

The Throttle Position Sensor (TPS) is mounted to the throttle body (Scheme 140)

Scheme 140

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

The TPS is located on the throttle body (Scheme 141)

Scheme 141

1. Remove air duct and tube at throttle body.
2. Disconnect TPS electrical connector.
3. Remove two TPS mounting bolts (screws) (Scheme 141)
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 TPS is attached to the throttle body (Scheme 139)

1. Disconnect the TPS electrical connector.
2. Remove the TPS mounting screws.
3. Remove the TPS.

The Throttle Position Sensor (TPS) is mounted to the throttle body (Scheme 142)

Scheme 142

The throttle shaft end of throttle body slides into a socket in TPS (Scheme 143) 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 143

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 slides into a socket in TPS (Scheme 144) 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 144

1. Install TPS and two retaining bolts (Scheme 145)
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.

The TPS is attached to the throttle body (Scheme 139)

The throttle shaft end of the throttle body slides into a socket in the TPS (Scheme 146) When indexed correctly, the TPS can rotate a few degrees to line up the mounting screw holes with the screw holes in the throttle body. If the sensor will not rotate into place, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS has slight tension when rotated to align the mounting holes.

Scheme 145

Scheme 146

1. Install TPS and mounting screws.
2. Attach electrical connector to the TPS.

See also:
• FUEL RAIL
• STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE
• AIR CLEANER HOUSING
• REMOVAL
• INSTALLATION
• ACCELERATOR PEDAL