Engine Controls - Component Remove/install/overhaul - 5.9l Diesel Dodge Pickup R2500

INTRODUCTION

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

Removal & Installation

1. Disconnect negative battery cables. Disconnect electrical connectors from PCM. The PCM is located at passenger's side rear corner of engine compartment, on the firewall. (Scheme 22) Remove mounting bolts and PCM.
2. To install, reverse removal procedure. Tighten mounting bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 22

INTERCOOLER

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

Removal

1. Remove grille. Remove front support bracket located above center of intercooler. On A/C-equipped models, discharge A/C system using approved refrigerant recovery/recycling equipment.
2. Disconnect and plug hoses and openings at condenser. Remove condenser. On all models, remove intercooler inlet and outlet ducts. (Scheme 23) Remove intercooler bolts. Pivot intercooler forward and upward to remove.

Inspection & Cleaning

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

Installation

To install, reverse removal procedure. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS. Evacuate and charge A/C system (if equipped).

Scheme 23

TURBOCHARGER

1. Disconnect negative battery cables. Disconnect air inlet tube and exhaust pipe from turbocharger. Disconnect intercooler inlet duct from turbocharger. (Scheme 23)
2. Disconnect and plug oil supply line and oil drain line at turbocharger. Remove turbocharger retaining nuts, turbocharger and gasket from exhaust manifold. Plug all air intake openings.

Disassembly & Reassembly

Turbocharger overhaul procedures should only be performed by authorized facility.

1. Apply anti-seize compound on turbocharger mounting studs. Using NEW gasket, install turbocharger. Install and tighten turbocharger retaining nuts to specification. See TORQUE SPECIFICATIONS.
2. Using NEW gasket, install oil drain line on turbocharger. Install and tighten oil drain line bolts to specification. See TORQUE SPECIFICATIONS. Pour 3 ozs. (60 cc) of clean engine oil into oil inlet on turbocharger while rotating turbine wheel in turbocharger. WARNING: DO NOT rotate turbine wheel in turbocharger with your finger, as sharp edges may exist.
3. Install oil supply line on turbocharger and tighten to specification. To install remaining components, reverse removal procedure. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS.

TURBOCHARGER WASTEGATE ADJUSTMENT

Note. For turbocharger wastegate adjustment, see CONTROL ROD ADJUSTMENT under TURBOCHARGER WASTEGATE in ADJUSTMENTS article.

Battery temperature sensor is snapped into the battery tray below driver's side battery. Remove driver's side battery. Disconnect wiring harness at battery temperature sensor. Pry battery temperature sensor upward, from battery tray. To install, reverse removal procedure.

Removal (Calif. Models With EGR)

1. Engine coolant temperature sensor is located on driver's side of engine, behind fuel filter/water separator, just below intake manifold. (Scheme 24)
2. Partially drain cooling system until coolant level is below the cylinder head. Remove fuel filter/water separator. See FUEL FILTER/WATER SEPARATOR & WATER-IN-FUEL SENSOR under FUEL SYSTEM.
3. Disconnect wiring harness electrical connector from engine coolant temperature sensor. Remove engine coolant temperature sensor from cylinder head.

1. Apply sealant on threads of engine coolant temperature sensor and install in cylinder head. Tighten engine coolant temperature sensor to specification. See TORQUE SPECIFICATIONS. CAUTION: Ensure engine is not running when refilling cooling system. Engine is equipped with a one-way check valve used to vent air from the cooling system. If engine is running the water pressure will hold one-way check valve closed and air will not be bled from cooling system.
2. Install wiring harness electrical connector on engine coolant temperature sensor. Reinstall fuel filter/water separator using proper procedure. Refill cooling system. DO NOT have engine running when refilling cooling system.

Scheme 24

ENGINE SPEED SENSOR

Note. Engine speed sensor may also be referred to as crankshaft position sensor.

1. Engine speed sensor is located on front of timing gear cover, just above vibration damper. (Scheme 25) Disconnect electrical wiring harness connector for engine speed sensor.
2. Note routing of electrical wiring harness for engine speed sensor. Remove electrical wiring harness retaining clips. Note location of spacers between engine speed sensor and timing gear cover. Remove bolts, engine speed sensor and spacers.

1. Install spacers and engine speed sensor with bolts finger tight. DO NOT tighten bolts, as engine speed sensor air gap between tip of engine speed sensor and vibration damper must be adjusted. CAUTION: Engine speed sensor MUST NOT be aligned with notches on vibration damper when adjusting engine speed sensor air gap or sensor will be damaged when engine is started. (Scheme 25)
2. Engine speed sensor air gap should be.049-.051" (1.25-1.30 mm). Install proper thickness Brass (non-magnetic) feeler gauge between tip of engine speed sensor and vibration damper.
3. Gently push engine speed sensor downward against Brass feeler gauge. Tighten engine speed sensor bolts to specification. See TORQUE SPECIFICATIONS. Remove feeler gauge and recheck air gap. Reinstall electrical wiring harness.

Scheme 25

1. Disconnect electrical connector from intake manifold air temperature sensor. (Scheme 26) Remove intake manifold air temperature sensor from intake manifold cover.
2. To install, reverse removal procedure. Tighten intake manifold air temperature sensor to specification. See TORQUE SPECIFICATIONS.

Scheme 26

Removal (A/T Models & M/T Models With EGR)

Disconnect electrical connector from bottom of Throttle Position (TP) sensor located on side of fuel injection pump. (Scheme 27) Remove bolts and TP sensor.

1. Install TP sensor on throttle lever bracket with electrical connector on TP sensor facing downward. The TP sensor is spring loaded and must be rotated counterclockwise until bolt holes are aligned when installing on throttle lever bracket.
2. Rotate TP sensor counterclockwise until bolt holes are aligned. Install and tighten bolts. Reinstall electrical connector. Operate throttle and check for binding in throttle linkage.
3. Check TP sensor adjustment. See THROTTLE POSITION SENSOR ADJUSTMENT under THROTTLE POSITION SENSOR in ADJUSTMENTS article.

Scheme 27

Removal & Installation (A/T Models)

Transmission governor pressure sensor is located in governor body on transmission valve body. See AUTOMATIC TRANSMISSIONS article in appropriate section.

TRANSMISSION SPEED SENSOR

Note. Transmission speed sensor may also be referred to as transmission output shaft speed sensor.

1. Transmission speed sensor is located on overdrive case at rear of transmission. Transmission speed sensor contains a 2-pin Black connector with a Dark Blue/Black wire and a Light Green/Black wire.
2. Remove transmission speed sensor with "O" ring from rear of transmission. To install, reverse removal procedure using NEW "O" ring. Tighten transmission speed sensor to specification. See TORQUE SPECIFICATIONS.

Transmission temperature sensor is located on transmission valve body, incorporated into governor pressure sensor. See appropriate AUTOMATIC TRANSMISSIONS section.

1. Raise and support vehicle. Vehicle speed sensor is located on transmission extension housing on 2WD models. (Scheme 28) On 4WD models, vehicle speed sensor is located on the transfer case.
2. Disconnect electrical connector from vehicle speed sensor. Remove retaining bolt and vehicle speed sensor with "O" ring from adapter. DO NOT remove adapter from transmission or transfer case.
3. To install, reverse removal procedure using NEW "O" ring. Ensure vehicle speed sensor is fully seated in adapter before tightening retaining bolt to specification. See TORQUE SPECIFICATIONS.

Scheme 28

Removal (A/T Models)

1. Raise and support vehicle. Disconnect 3-pin electrical connector from park/neutral switch. Park/neutral switch is located on driver's side of transmission case, near shift linkage.
2. Unscrew park/neutral switch from transmission case. Remove seal ring from park/neutral switch.

1. Apply parking brake. Place shift lever in Park. Ensure park/neutral switch operating levers in transmission are centered in the park/neutral switch opening on transmission case.
2. Using NEW seal ring, install park/neutral switch. Tighten park/neutral switch to specification. See TORQUE SPECIFICATIONS. Install electrical connector. Add Mopar Plus 7176 ATF as necessary.

TRANSMISSION OVERDRIVE SWITCH

Note. Transmission overdrive switch may also be referred to as overdrive/override switch, OD switch or overdrive off switch.

1. Transmission overdrive switch is located in switch assembly on instrument panel, just above the stereo. Disconnect negative battery cables.
2. Remove cup holder, ashtray and bracket for removal of instrument cluster bezel. Remove instrument cluster bezel from instrument panel by prying at designated snap areas. (Scheme 29)
3. Disconnect electrical connectors from instrument cluster bezel. Remove instrument cluster bezel. Remove screws holding switch assembly on instrument panel.
4. Disconnect electrical connectors from rear of switch assembly. Release retaining tabs and remove transmission overdrive switch from switch assembly. To install, reverse removal procedure.

Scheme 29

A/C CLUTCH RELAY

Note. A/C clutch relay may also be referred to as A/C relay.

A/C clutch relay is located in power distribution center at driver's side front corner of engine compartment, near the battery.

ASD relay is located in power distribution center at driver's side front corner of engine compartment, near the battery.

Disconnect negative battery cables. Disconnect electrical connector at appropriate relay. (Scheme 30) Remove relay from mounting bracket. To install, reverse removal procedure.

Scheme 30

INTAKE MANIFOLD AIR HEATER RELAYS

Note. Intake manifold air heater relays may also be referred to as intake air heater relays.

1. Intake manifold air heater relays are mounted on inner wheelwell, below driver's side battery. (Scheme 31) Disconnect negative battery cables.
2. Note location of wiring on intake manifold air heater relays for installation reference. Disconnect electrical connectors at intake manifold air heater relays.
3. Remove bolts and intake manifold air heater relay assembly. Both relays and mounting bracket are replaced as an assembly. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 31

TRANSMISSION RELAY

Note. Transmission relay may also be referred to as transmission control relay.

Transmission relay is located in power distribution center at driver's side front corner of engine compartment, near the battery.

Removal (Calif. Models Only)

1. EGR valve vacuum regulator solenoid is located on driver's side of engine, just in front of EGR valve. (Scheme 32)
2. Disconnect electrical connector and vacuum hoses at EGR valve vacuum regulator solenoid. Remove mounting bolt and EGR valve vacuum regulator solenoid with mounting bracket.
3. To install, reverse removal procedure. Tighten mounting bolt to specification. See TORQUE SPECIFICATIONS.

Scheme 32

Transmission governor pressure solenoid is located on transmission valve body. See appropriate AUTOMATIC TRANSMISSION article in TRANSMISSION SERVICE & REPAIR section for servicing of valve body and components.

Overdrive solenoid and TCC solenoid are located in solenoid assembly on transmission valve body. See AUTOMATIC TRANSMISSIONS article appropriate section for servicing of valve body and components.

FUEL LINE DISCONNECT FITTINGS

Note. Fuel lines may contain single tab, dual tab or plastic retainer ring disconnect fitting. (Scheme 33) Determine type of disconnect fitting used and use proper procedure for proper disconnect fitting.

Scheme 33

Removal & Installation (Single Tab)

1. Disconnect negative battery cables. Ensure disconnect fitting and fuel lines are clean. Note location of release tab and pull tab on disconnect fitting. (Scheme 33) CAUTION: Release tab must be pressed downward before removing pull tab or pull tab will be damaged.
2. Press release tab downward. Use screwdriver to pry pull tab upward until pull tab separates from disconnect fitting. Remove disconnect fitting from fuel line. Inspect components for damage. If disconnect fitting is damaged, entire assembly must be replaced, as only pull tab can be replaced.
3. To install, ensure fuel line and disconnect fitting are clean. Lubricate fuel line and disconnect fitting with engine oil. Install disconnect fitting on fuel line until disconnect fitting bottoms on fuel line.
4. Install NEW pull tab until pull tab locks in disconnect fitting. DO NOT reuse old pull tab. Pull on fuel line and disconnect fitting to ensure components are properly locked together. Reconnect negative battery cables. Start engine and check for leaks.

Removal & Installation (Dual Tab)

1. Disconnect negative battery cables. Ensure disconnect fitting and fuel lines are clean. Note location of tabs on disconnect fitting. (Scheme 33)
2. Squeeze both tabs against disconnect fitting. Pull disconnect fitting from fuel line. Inspect components for damage. If disconnect fitting is damaged, entire assembly must be replaced.
3. To install, ensure fuel line and disconnect fitting are clean. Lubricate fuel line and disconnect fitting with engine oil. Install disconnect fitting on fuel line until click sound is heard.
4. Pull on fuel line and disconnect fitting to ensure components are properly locked together. Reconnect negative battery cables. Start engine and check for leaks.

Removal & Installation (Plastic Retainer Ring)

1. Disconnect negative battery cables. Ensure disconnect fitting and fuel lines are clean. Note location of plastic retainer ring on disconnect fitting. (Scheme 33) NOTE: Plastic retainer ring must be pressed evenly into disconnect fitting. If plastic retainer is not even, it will be difficult to remove disconnect fitting from fuel line.
2. Firmly push disconnect fitting toward the fuel line while pushing plastic retainer ring evenly into disconnect fitting. With plastic retainer ring fully depressed, pull disconnect fitting from fuel line.
3. Inspect components for damage. If disconnect fitting is damaged, entire assembly must be replaced.
4. To install, ensure fuel line and disconnect fitting are clean. Lubricate fuel line and disconnect fitting with engine oil. Install disconnect fitting on fuel line until click sound is heard.
5. Pull on fuel line and disconnect fitting to ensure components are properly locked together. Reconnect negative battery cables. Start engine and check for leaks.

FUEL LINE BLEEDING

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

1. To bleed low-pressure fuel lines and fuel filter/water separator, loosen fuel bleed bolt. Fuel bleed bolt is located in center of fuel supply line banjo bolt on top of fuel filter/water separator. (Scheme 34)
2. Operate rubber primer button on fuel transfer pump until steady fuel stream flows from fuel bleed bolt. Tighten fuel bleed bolt to specification. See TORQUE SPECIFICATIONS. CAUTION: Ensure parking brake is applied and transmission is in Neutral before bleeding high-pressure fuel lines.
3. To bleed high-pressure fuel lines, ensure parking brake is applied and transmission is in Neutral, as engine may start when cranking to bleed air. Carefully loosen high-pressure fuel line nut at fuel injector. CAUTION: DO NOT operate starter for more than 30 seconds when bleeding high-pressure fuel lines. Allow 2-minute intervals between starter operations.
4. Operate starter until steady fuel flow exists at high-pressure fuel line. Tighten high-pressure fuel line nut to specification. See TORQUE SPECIFICATIONS. Start engine. Repeat procedure on each high-pressure fuel line until engine operates smoothly.

Scheme 34

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

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

1. Place drain pan below drain tube at fuel filter/water separator. (Scheme 34) Rotate handle on drain valve forward, toward front of vehicle to drain fuel from fuel filter/water separator. Drain valve is located at top of fuel filter/water separator. (Scheme 34)
2. Disconnect drain tube from drain valve. Disconnect electrical connector for Water-In-Fuel (WIF) sensor at bottom of fuel filter/water separator. (Scheme 34)
3. Support canister for fuel filter/water separator and remove canister nut from top of filter mounting head. (Scheme 34) Remove canister with fuel filter/water separator and seal ring from filter mounting head. Remove fuel filter/water separator from canister.
4. Remove "O" ring from top of shaft inside the canister. Remove bolts and drain valve from canister (if necessary).
5. Check the 2 probes inside the canister on end of WIF sensor for contamination. Clean probes if contaminated. If contamination cannot be removed from the probes, replace WIF sensor. If replacing WIF sensor, remove WIF sensor and "O" ring from canister.

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

FUEL TANK MODULE & IN-TANK FUEL FILTER

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

1. Raise and support vehicle. Disconnect negative battery cables. Drain fuel tank. Remove fuel tank filler tube bolts from body. Support fuel tank with transmission jack. Remove fuel tank straps and heat shields (if equipped).
2. Slightly lower fuel tank for access to fuel lines and electrical connector at fuel tank module. Disconnect electrical connector and fuel lines at fuel tank module. Use proper procedure when disconnecting fuel lines, see FUEL LINE DISCONNECT FITTINGS under FUEL SYSTEM.
3. Note direction of fuel line connections on fuel tank module for installation reference. Using spanner wrench, unscrew plastic fuel tank module lock nut from fuel tank.
4. Remove fuel tank module and gasket from fuel tank. Pry retaining tabs back and remove in-tank fuel filter from fuel tank module.

1. Install NEW in-tank fuel filter on fuel tank module. Ensure retaining tabs are fully engaged. Using NEW gasket, install fuel tank module in fuel tank.
2. Position fuel tank module so fuel line connections and electric connection are facing toward driver's side of vehicle. Install and tighten plastic fuel tank module lock nut to specification. See TORQUE SPECIFICATIONS.
3. Install fuel lines on fuel tank module using proper procedure. See FUEL LINE DISCONNECT FITTINGS under FUEL SYSTEM. Install electrical connector on fuel tank module. Reinstall fuel tank. Tighten fuel tank strap nuts to specification. See TORQUE SPECIFICATIONS. Reconnect negative battery cables.

1. Remove nameplate located above rocker lever covers. Remove fuel injector drain line-to-fuel injector banjo bolt and seal washer from each fuel injector. Plug all fuel openings.
2. Remove fuel injector drain line assembly retaining clamp at rear of intake manifold. Remove fuel injector drain line bolt with seal washers at filter mounting head. (Scheme 34) Remove fuel injector drain line assembly.

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

1. Disconnect negative battery cables. Remove starter. Disconnect electrical connector at fuel heater. Fuel heater is located below fuel filter/water separator. (Scheme 34)
2. Place drain pan below pre-filter and fuel heater. Pre-filter is located on bottom of fuel heater. (Scheme 34)
3. Unscrew pre-filter with seal ring from fuel heater by using hex area on bottom of pre-filter. Remove fuel heater and seal rings from housing.
4. Ensure filter screen in pre-filter is clean. To install, reverse removal procedure using NEW seal rings. Tighten starter mounting bolts to specification. See TORQUE SPECIFICATIONS.

FUEL INJECTOR

1. Disconnect negative battery cables. Remove nameplate located above rocker lever covers. Ensure area around fuel injector and high-pressure fuel line is clean. Disconnect high-pressure fuel line at fuel injector. It may be necessary to remove high-pressure fuel lines from fuel injection pump for access to fuel injector.
2. If removing high-pressure fuel lines from fuel injection pump, mark high-pressure fuel line location for installation reference. Remove high-pressure fuel line from fuel injection pump.
3. Remove fuel injector drain line-to-fuel injector banjo bolt and seal washer from each fuel injector. Plug all fuel openings. Remove fuel injector drain line assembly retaining clamp at rear of cylinder head.
4. Remove fuel injector drain line bolt with seal washers at filter mounting head. (Scheme 34) Ensure area around fuel injector is clean. CAUTION: If area around fuel injector retaining nut and fuel injector is rusty, fuel injector may rotate when removing fuel injector retaining nut. Fuel injector and cylinder head may be damaged if fuel injector rotates during removal of fuel injector retaining nut. Apply penetrating oil on fuel injector and retaining nut if rust exists before attempting fuel injector retaining nut removal.
5. Hold body of fuel injector with wrench while removing fuel injector retaining nut from cylinder head. If fuel injector retaining nut can be removed, go to step 7). If fuel injector retaining nut cannot be removed, remove rubber seal ring from groove on top of fuel injector retaining nut.
6. Spray area around fuel injector retaining nut and fuel injector with penetrating oil. Hold body of fuel injector with wrench while removing fuel injector retaining nut from cylinder head. Go to next step.
7. Remove rubber seal ring from groove on top of fuel injector retaining nut (if not previously removed). Using hammer and Brass drift, lightly tap body of fuel injector to loosen fuel injector in cylinder head.
8. Pull fuel injector from cylinder head. It may be necessary to use Fuel Injector Puller (3823276) to pull fuel injector from cylinder head. If fuel injector is difficult to pull from cylinder head, spray carburetor cleaner around outside of fuel injector while trying to pull fuel injector from cylinder head. This will aid in dissolving carbon deposits at fuel injector and cylinder head. Remove Copper sealing washer (located below fuel injector) from cylinder head if it was not removed with fuel injector.

1. Clean fuel injector bore on cylinder head with wire brush. Apply light coat of engine oil on NEW Copper sealing washer. Install NEW Copper sealing washer on spray tip of fuel injector. Engine oil is used to aid holding sealing washer in place. Coat threads on fuel injector retaining nut and top of fuel injector body with anti-seize compound. CAUTION: Ensure protruding side of fuel injector aligns with notch area on cylinder head before tightening fuel injector retaining nut.
2. Install fuel injector in original position. Ensure protruding side of fuel injector aligns with notch area on cylinder head. Install and tighten fuel injector retaining nut to specification. See TORQUE SPECIFICATIONS.
3. Once fuel injector retaining nut is tightened, install NEW rubber seal ring in groove on top of fuel injector retaining nut. Rubber seal ring is used to prevent water from entering bore on cylinder head.
4. To install remaining components, reverse removal procedure using NEW seal washers. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Bleed high-pressure fuel lines. See FUEL LINE BLEEDING under FUEL SYSTEM.

FUEL INJECTION PUMP

Note. A NEW or remanufactured fuel injection pump should have a NEW overflow valve installed on fuel injection pump. (Scheme 35) Overflow valve is used to secure fuel return line on fuel injection pump. DO NOT install used overflow valve on a NEW or remanufactured fuel injection pump. If used fuel injection pump is being sent out for testing or calibration, ensure the original overflow valve is installed in used fuel injection pump.

Scheme 35

Scheme 36

Scheme 37

1. Disconnect negative battery cables. Disconnect necessary electrical connections at fuel injection pump. On Calif. models, remove EGR tube with gaskets from EGR valve and exhaust manifold. (Scheme 32)
2. Disconnect intercooler outlet duct from air inlet housing. (Scheme 23) Remove clamp and position engine oil dipstick tube aside. Remove cable nuts and disconnect cables from intake manifold air heater. (Scheme 36)
3. Remove bolts, air inlet housing and gasket. Air inlet housing may also be referred to as intake manifold. Remove throttle lever bracket with control cables from side of fuel injection pump. Disconnect line from AFC. AFC is located on top of fuel injection pump. (Scheme 40)
4. Remove fuel injection pump fuel supply line and gaskets. Fuel supply line fits between fuel injection pump and filter mounting head for fuel filter/water separator. Remove overflow valve and fuel return line with gaskets from fuel injection pump. (Scheme 35) DO NOT remove retainer from center of overflow valve. (Scheme 35)
5. Mark location of high-pressure fuel lines for installation reference. Remove high-pressure fuel lines from fuel injection pump. Disconnect oil supply line from side of fuel injection pump.
6. Remove oil fill tube and adapter elbow from front of timing gear cover by rotating assembly counterclockwise (viewed from front of engine).
7. Disconnect air inlet tube from turbocharger and air filter housing. Engine may be rotated by removing dust plug from transmission adapter plate and installing Engine Barring Tool (7471B) in transmission adapter plate. (Scheme 37) CAUTION: Use care when engaging timing pin to avoid breaking tip of timing pin. Ensure timing pin is disengaged before rotating engine.
8. Note location of timing pin. (Scheme 37) Timing pin is located on back of gear housing, just above vacuum pump and below fuel injection pump. Push timing pin toward front of engine.
9. Using engine barring tool, slowly rotate engine clockwise (viewed from front of engine) while holding tension on timing pin. Rotate engine until timing pin engages machined hole on camshaft gear. This positions cylinder No. 1 at TDC on compression stroke. CAUTION: To prevent damage to timing pin, ensure timing pin is disengaged from camshaft gear before attempting to loosen fuel injection pump drive gear nut. DO NOT allow engine to rotate when loosening fuel injection pump drive gear nut.
10. Disengage timing pin from camshaft gear. While holding engine from rotating with engine barring tool, loosen fuel injection pump drive gear nut. To prevent nut from falling inside timing gear cover, install a pencil-type magnet on end of shaft at fuel injection pump. (Scheme 38) NOTE: If pencil-type magnet is not available, place shop towel below fuel injection pump drive gear nut and timing gear cover to prevent nut from falling into engine.
11. Remove fuel injection pump drive gear nut and washer from end of shaft at fuel injection pump. DO NOT allow nut or washer to fall into timing gear cover.
12. Using gear puller, pull fuel injection pump drive gear forward just enough to loosen gear from tapered area on shaft of fuel injection pump. (Scheme 39) DO NOT pull fuel injection pump drive gear too far forward or timing gear cover may be damaged.
13. Remove fuel injection pump-to-lower mounting bracket bolts. Remove fuel injection pump-to-gear housing nuts. Remove fuel injection pump. Use care not to scratch or damage shaft of fuel injection pump during removal.

Scheme 38

Scheme 39

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

1. If installing original fuel injection pump, shaft on fuel injection pump must be properly positioned by engaging pump timing pin to provide proper fuel injection pump timing. NEW or rebuilt fuel injection pumps should be shipped with shaft on fuel injection pump properly positioned and pump timing pin engaged.
2. To position shaft on fuel injection pump, remove access plug from side of fuel injection pump. (Scheme 40) Pump timing pin is located in bore behind access plug. (Scheme 40) Remove pump timing pin from fuel injection pump.
3. Rotate shaft on fuel injection pump until pump timing tooth is visible in center of access plug bore on fuel injection pump. Install pump timing pin so slot in pump timing pin engages with pump timing tooth. (Scheme 40) Temporarily install access plug. NOTE: It may be necessary to slightly rotate shaft on fuel injection pump when engaging pump timing pin. DO NOT force slot on pump timing pin onto pump timing tooth.
4. If installing original fuel injection pump, check condition of "O" ring on front of fuel injection pump. Replace "O" ring (if necessary).
5. When installing original, NEW or rebuilt fuel injection pumps, ensure injection pump drive gear-to-shaft mating surfaces are clean and free of oil. Lubricate "O" ring on fuel injection pump and "O" ring sealing area on fuel injection pump flange opening in gear housing with engine oil to allow for ease of fuel injection pump installation. CAUTION: Ensure fuel injection pump drive gear-to-shaft mating surfaces are clean and free of oil to provide proper seating of fuel injection pump drive gear on shaft of fuel injection pump.
6. Install fuel injection pump on mounting studs at rear of gear housing. Ensure fuel injection pump is flat against gear housing. DO NOT tighten fuel injection pump-to-gear housing nuts if fuel injection pump is not fully engaged into gear housing. Install fuel injection pump-to-gear housing nuts finger tight. DO NOT tighten nuts at this time. CAUTION: Ensure fuel injection pump-to-gear housing nuts are tightened to specification before tightening fuel injection pump-to-lower mounting bracket bolts. Nuts and bolts must be tightened in proper sequence to prevent damage to fuel injection pump or gear housing.
7. Install fuel injection pump-to-lower mounting bracket bolts finger tight. Tighten fuel injection pump-to-gear housing nuts to specification. See TORQUE SPECIFICATIONS. Tighten fuel injection pump-to-lower mounting bracket bolts.
8. Install pencil-type magnet on end of shaft on fuel injection pump. Install washer and fuel injection pump drive gear nut. Remove magnet.
9. Tighten fuel injection pump drive gear nut to preliminary torque of 11 ft. lbs. (15 N.m). DO NOT overtighten nut, as pump timing pin may be damaged. This is not the final tightening torque.
10. Disengage timing pin from camshaft gear. Remove access plug and pump timing pin from side of fuel injection pump. (Scheme 40) While preventing engine from rotating by using engine barring tool, tighten fuel injection pump drive gear nut to final torque of 122 ft. lbs. (165 N.m).
11. Fuel injection pump timing must now be checked. Ensure timing pin is disengaged from camshaft gear. Rotate engine clockwise (viewed from front of engine) until cylinder No. 1 is at TDC on compression stroke and timing pin engages machined hole on camshaft gear. Ensure timing pin fully engages machined hole on camshaft gear.
12. Ensure pump timing tooth is centered in access plug opening on fuel injection pump. Insert pump timing pin with slot facing inward. Ensure slot on pump timing pin engages with pump timing tooth. (Scheme 40)
13. If pump timing pin engages with pump timing tooth, proceed to step 16). If pump timing pin will not engage with pump timing tooth, remove fuel injection pump drive gear nut and washer. DO NOT allow engine to rotate when removing fuel injection pump drive gear nut.
14. Using gear puller, pull fuel injection pump drive gear from tapered area on shaft on fuel injection pump. Rotate shaft of fuel injection pump until pump timing tooth is centered in access plug opening on fuel injection pump. Ensure pump timing pin engages with pump timing tooth.
15. Install washer and fuel injection pump drive gear nut. Tighten fuel injection pump drive gear nut to preliminary torque of 11 ft. lbs. (15 N.m). Disengage timing pin from camshaft gear and remove pump timing pin from injection pump bore. Tighten fuel injection pump drive gear nut to 122 ft. lbs. (165 N.m) while holding engine from rotating. Ensure pump timing pin engages with pump timing tooth. Proceed to next step.
16. Install pump timing pin in the disengaged position with slot facing outward. (Scheme 40) Install sealing washer and access plug. Tighten access plug to specification. See TORQUE SPECIFICATIONS.
17. Install fuel return line, gaskets and overflow valve on fuel injection pump. A NEW or remanufactured fuel injection pump should have a NEW overflow valve installed on fuel injection pump. (Scheme 35) DO NOT install used overflow valve on a NEW or remanufactured fuel injection pump. Tighten overflow valve to specification. See TORQUE SPECIFICATIONS.
18. To install remaining components, reverse removal procedure using NEW gaskets. Tighten bolts/nuts to specification. CAUTION: On Calif. models, when installing EGR tube on EGR valve, ensure EGR tube-to-EGR valve bolts are alternately tightened to specification so EGR tube is installed evenly on EGR valve. CAUTION: NEW or rebuilt fuel injection pumps must be pre-lubricated before operating to prevent premature governor wear.
19. If installing NEW or rebuilt fuel injection pump, remove oil fill plug from top of fuel injection pump. (Scheme 40) Add 25 ounces (.74 liter) of clean engine oil to fuel injection pump. Install and tighten oil fill plug to specification. See TORQUE SPECIFICATIONS.
20. On all fuel injection pumps, install and bleed fuel lines. See FUEL LINE BLEEDING under FUEL SYSTEM. Check for proper throttle linkage adjustment. See LINKAGE ROD ADJUSTMENT under THROTTLE LINKAGE in ADJUSTMENTS article.
21. If necessary to adjust low idle speed, see LOW IDLE SPEED under IDLE SPEED in ADJUSTMENTS article. On A/T models and M/T models with EGR, check throttle position sensor adjustment. See THROTTLE POSITION SENSOR ADJUSTMENT under THROTTLE POSITION SENSOR in ADJUSTMENTS article. On all models, adjust engine oil level (if necessary).

Scheme 40

1. Disconnect electrical connector from fuel shutdown solenoid. Fuel shut down solenoid is located on side of fuel injection pump. (Scheme 41) Remove clip from shaft on fuel shutdown solenoid. (Scheme 41) Remove mounting bolts and fuel shutdown solenoid.
2. To install, reverse removal procedure. After installing fuel shutdown solenoid, fuel shutdown solenoid shaft adjustment must be checked.

Fuel Shutdown Solenoid Shaft Adjustment

1. Turn ignition on. Pull upward on solenoid lever and hold solenoid lever in the upward position. (Scheme 41) If fuel shutdown solenoid is operating correctly, solenoid lever should remain in upward position with ignition on.
2. Measure distance from bottom of mounting bracket to end of lever pin. (Scheme 42) Distance should be 2.64" (67.0 mm). If distance is incorrect, loosen shaft lock nut and rotate adjustment nut until correct distance is obtained. (Scheme 42) Tighten shaft lock nut and recheck the distance.

Scheme 41

Scheme 42

FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE

Fuel tank pressure relief/rollover valve is incorporated into fuel tank module. For fuel tank module servicing procedure, see FUEL TANK MODULE & IN-TANK FUEL FILTER under FUEL SYSTEM.

1. Disconnect negative battery cables. Remove starter. Ensure area around fuel transfer pump and lines are clean. Fuel transfer pump is located on driver's side of engine. (Scheme 34)
2. Place drain pan below fuel transfer pump. Disconnect fuel line at fuel transfer pump and fuel heater. (Scheme 34) Remove rubber fuel hose located between fuel heater and fuel transfer pump. CAUTION: Cylinder No. 1 must be at TDC on compression stroke before removing or installing fuel transfer pump. This is done to ensure engine camshaft is properly positioned so lobe on camshaft is pointing away from plunger on fuel transfer pump. If lobe on camshaft is against plunger on fuel transfer pump, removal or installation of fuel transfer pump will be difficult and fuel transfer pump may be damaged.
3. To place cylinder No. 1 at TDC on compression stroke, remove dust plug from transmission adapter plate and installing Engine Barring Tool (7471B) in transmission adapter plate. (Scheme 37) Engine barring tool is used to rotate engine. CAUTION: Use care when engaging timing pin to avoid breaking tip of timing pin. Ensure timing pin is disengaged before rotating engine.
4. Note location of timing pin. (Scheme 37) Timing pin is located on back of gear housing, just above vacuum pump and below fuel injection pump. Push timing pin toward front of engine.
5. Using engine barring tool, slowly rotate engine clockwise (viewed from front of engine) while holding tension on timing pin. Rotate engine until timing pin engages machined hole on camshaft gear. This positions cylinder No. 1 at TDC on compression stroke. CAUTION: To prevent damage to timing pin, ensure timing pin is disengaged from camshaft gear before rotating engine.
6. Once cylinder No. 1 is at TDC on compression stroke, disengage timing pin from camshaft gear. Continue to rotate engine clockwise (viewed from front of engine) an additional 180-270 degrees. This positions lobe on camshaft away from plunger on fuel transfer pump. CAUTION: When removing fuel transfer pump, DO NOT allow plunger in fuel transfer pump to catch on cylinder block and fall into the engine.
7. Remove bolts and fuel transfer pump with fuel heater and gasket. Use care not to allow plunger in fuel transfer pump to catch on cylinder block and fall into the engine.

1. To install, reverse removal procedure. Ensure gasket sealing surfaces are clean. Using NEW gasket, install fuel transfer pump and fuel heater on cylinder block. Install bolts in fuel transfer pump. Tighten bolts evenly to specification. See TORQUE SPECIFICATIONS. CAUTION: Bolts must be tighten evenly when installing fuel transfer pump to prevent damage to fuel transfer pump, as plunger is being compressed when bolts are tightened.
2. Tighten fuel lines to specification. Install starter and negative battery cables. Bleed low-pressure fuel lines. See FUEL LINE BLEEDING under FUEL SYSTEM.

HIGH-PRESSURE FUEL LINES

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

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

Removal & Installation (Calif. Models Only)

1. EGR tube is located between EGR valve and exhaust manifold. (Scheme 32) Remove bolts, EGR tube and gaskets. CAUTION: When installing EGR tube on EGR valve, ensure EGR tube-to-EGR valve bolts are alternately tightened to specification so EGR tube is installed evenly on EGR valve.
2. To install, reverse removal procedure using NEW gaskets. Tighten bolts/nuts evenly to specification. See TORQUE SPECIFICATIONS. Ensure EGR tube is installed evenly on EGR valve.

EGR valve is located on side of intake manifold. (Scheme 32) Disconnect vacuum line from EGR valve. Remove EGR tube-to-EGR valve bolts and EGR valve-to-intake manifold bolts. Remove EGR valve and gaskets.

1. Ensure all sealing surfaces are clean. Using NEW gasket, install EGR valve on EGR tube with bolts finger tight. DO NOT tighten bolts at this time.
2. Using NEW gasket, install EGR valve on intake manifold with bolts finger tight. DO NOT tighten bolts at this time. Lower mounting bolt hole on EGR valve is slotted to allow for movement of EGR valve. Rotate EGR valve so EGR valve is square with EGR tube. Tighten EGR valve-to-intake manifold bolts to specification. See TORQUE SPECIFICATIONS. CAUTION: When installing EGR valve on EGR tube, ensure EGR tube-to-EGR valve bolts are alternately tightened to specification so EGR tube is installed evenly on EGR valve.
3. Tighten EGR tube-to-EGR valve bolts evenly to specification. See TORQUE SPECIFICATIONS. Ensure EGR tube is installed evenly on EGR valve. Install vacuum line on EGR valve.

1. EGR valve one-way check valve is located between EGR valve and EGR valve vacuum regulator solenoid on driver's side of engine. (Scheme 32)
2. Note direction of check valve installation and vacuum hose connections for installation reference. Disconnect vacuum hoses and remove EGR valve one-way check valve.
3. To install, reverse removal procedure. Ensure EGR valve one-way check valve is installed with vacuum ports in correct location. (Scheme 43)

Scheme 43

Removal & Installation (Calif. Models)

See EGR VALVE VACUUM REGULATOR SOLENOID under RELAYS & SOLENOIDS.

INTAKE MANIFOLD AIR HEATER

Note. Intake manifold air heater may also be referred to as intake air heater. Intake manifold air heater is incorporated into intake manifold cover, located below air inlet housing.

1. Disconnect negative battery cables. Remove intercooler outlet duct from air inlet housing. (Scheme 23)
2. Remove bolts, air inlet housing and gasket from intake air heater. Air inlet housing may be referred to as intake manifold.
3. On Calif. models, remove EGR tube. See EGR TUBE under EMISSION SYSTEMS & SUB-SYSTEMS.
4. On all models, remove high-pressure fuel lines for access to intake manifold cover. See HIGH-PRESSURE FUEL LINES under FUEL SYSTEM. Disconnect necessary electrical connectors for removal of intake manifold cover. Remove bolts, intake manifold cover with intake manifold air heater and gasket.

1. To install, reverse removal procedure using NEW gaskets. Apply thread sealant on threads of intake manifold cover bolts before installing. Tighten all bolts to specification. See TORQUE SPECIFICATIONS. CAUTION: On Calif. models, when installing EGR tube on EGR valve, ensure EGR tube-to-EGR valve bolts are alternately tightened to specification so EGR tube is installed evenly on EGR valve.
2. Bleed high-pressure fuel lines. See FUEL LINE BLEEDING under FUEL SYSTEM.

See INTAKE MANIFOLD AIR HEATER RELAYS under RELAYS & SOLENOIDS.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS