Engine Controls - Component Remove/install/overhaul - 8.0l Dodge Pickup R2500

INTRODUCTION

Removal, overhaul and installation procedures (when provided by manufacturer) are covered in this article. If component removal and installation is basically an unbolt and bolt-on procedure, only a torque specification may be provided.

Removal & Installation

For PCM location, see PCM LOCATION table. Disconnect negative battery terminal. Disconnect PCM connectors. Remove bolts and PCM. To install, reverse removal procedure.

PCM LOCATION

CAMSHAFT POSITION SENSOR

See CAMSHAFT POSITION (CMP) SENSOR under IGNITION SYSTEM.

CRANKSHAFT POSITION SENSOR

See CRANKSHAFT POSITION (CKP) SENSOR under IGNITION SYSTEM.

HEATED OXYGEN SENSOR (HO2S)

Removal

HO2S is located in exhaust pipe, before or after catalytic converter. Raise and support vehicle. Disconnect HO2S connector. Using HO2S Remover/Installer (C-4907), remove HO2S.

Installation

1. If installing original or used HO2S, apply anti-seize compound on threads of sensor. New HO2S is already coated with anti-seize compound. DO NOT add any additional anti-seize compound to threads of new HO2S.
2. Using remover/installer, install and tighten HO2S to specification. See TORQUE SPECIFICATIONS. Install electrical connector.

1. Partially drain cooling system. Disconnect Engine Coolant Temperature (ECT) sensor connector. Sensor is mounted in intake manifold, near thermostat housing and connector contains a Black/Light Blue wire and a Tan/Black wire. Remove ECT sensor.
2. To install, reverse removal procedure. Tighten ECT sensor to specification. See TORQUE SPECIFICATIONS. Fill cooling system.

1. Remove air cleaner assembly. Disconnect Intake Air Temperature (IAT) sensor connector.
2. Sensor is located at left side of manifold near front of throttle body.
3. Remove IAT sensor. To install sensor, reverse removal procedure. Tighten sensor to specification. See TORQUE SPECIFICATIONS.

Disconnect MAP sensor connector. MAP sensor is located in right upper side of intake manifold. Remove MAP sensor bolts. Remove MAP sensor from intake manifold.

If installing original MAP sensor, check condition of MAP sensor gasket. If gasket is damaged, replace MAP sensor. Lightly lubricate sensor gasket with clean engine oil. Clean sensor opening in intake manifold. Install MAP sensor. Reconnect MAP sensor connector.

Raise and support vehicle. Park/Neutral Position (PNP) switch is located in transmission case. Position drain pan underneath switch. Disconnect PNP switch connector. Unscrew PNP switch from transmission case. Remove "O" ring seal ring from PNP switch.

1. Move shift lever from Park to Neutral positions. Ensure PNP switch operating levers in transmission are centered in the PNP switch opening on transmission case.
2. Install new "O" ring seal onto PNP switch. Lightly oil "O" ring with clean engine oil. Install PNP switch and tighten to specification. See TORQUE SPECIFICATIONS. Install electrical connector. Fill transmission to proper level with Mopar ATF Plus Type 7176 fluid.

1. Vehicle Speed Sensor (VSS) is mounted on left side of transmission extension housing. Raise and support vehicle. Disconnect VSS connector.
2. Remove retaining bolt. Remove VSS (pull straight out) from speedometer pinion gear adapter. DO NOT remove gear adapter from transmission.
3. To install, reverse removal procedure. Use new "O" ring. Ensure VSS is fully seated in gear adapter. Tighten retaining bolt to specification. See TORQUE SPECIFICATIONS.

Relays are located in Power Distribution Center (PDC). PDC is located near battery in left front corner of engine compartment.

1. The Evaporative Emission (EVAP) purge solenoid is located at rear of intake manifold. Mark location of EVAP purge solenoid vacuum hoses for installation reference.
2. Disconnect vacuum hoses and electrical connector from EVAPpurge solenoid. Lift EVAP purge solenoid from mounting bracket. To install, reverse removal procedure.

CMP sensor is located on left side of timing chain cover. Disconnect CMP sensor connector. Remove CMP sensor mounting bolt. Using 2 small screwdrivers, use a rocking motion and carefully pry sensor from timing chain cover. Remove sensor.

Installation (New CMP Sensor)

1. Lightly lubricate sensor "O" ring with clean engine oil. Using a 1/2" wide metal ruler, measure distance between camshaft sprocket and sensor mounting surface. (Scheme 16)
2. If distance is about 1.818" (46.18 mm), go to next step. If distance is about 2.018" (51.26 mm), use a socket and ratchet and rotate crankshaft until distance between camshaft sprocket and sensor mounting surface is 1.818" (46.18 mm). Go to next step.
3. Using a slight rocking action, install new sensor into timing chain cover. Push (DO NOT twist) sensor into timing chain cover until rib material on sensor contacts camshaft sprocket. (Scheme 17)
4. Install sensor mounting bolt and tighten to specification. See TORQUE SPECIFICATIONS. Connect CMP sensor connector. When engine is started, rib material will be sheared off face of sensor. This will automatically set sensor air gap.

Scheme 16

Scheme 17

Installation (Original CMP Sensor)

1. This procedure is to used only if original (used) CMP sensor is being reinstalled. Check face of CMP sensor. If any original rib material is present, use a razor and remove rib material until face of sensor is flat. (Scheme 17) DO NOT remove more material than is necessary. CAUTION: Due to high magnetic field and possible electrical damage to CMP sensor, DO NOT use an electric grinder to remove rib material from face of sensor.
2. Clean face of sensor. Install new paper spacer on face of CMP sensor. Use only paper spacer designed specifically for CMP sensors. DO NOT fabricate a paper spacer. Paper spacer is used to set sensor depth.
3. Using a 1/2" wide metal ruler, measure distance between camshaft sprocket and sensor mounting surface. (Scheme 16)
4. If distance is about 1.818" (46.18 mm), go to next step. If distance is about 2.018" (51.26 mm), use a socket and ratchet and rotate crankshaft until distance between camshaft sprocket and sensor mounting surface is 1.818" (46.18 mm). Go to next step.
5. Lightly lubricate sensor "O" ring with clean engine oil. Using a slight rocking action, install sensor into timing chain cover. Push (DO NOT twist) sensor into timing chain cover until paper spacer on sensor face contacts camshaft sprocket. DO NOT install sensor mounting bolt at this time.
6. Using a scribe, scratch a line into timing chain cover to indicate depth of sensor. (Scheme 18) Remove sensor from timing chain cover. Remove paper spacer from face of sensor. Again, lightly lubricate sensor "O" ring with clean engine oil.
7. Using a slight rocking action, install sensor into timing chain cover until sensor is aligned to scribe line. Install sensor mounting bolt and tighten to specification. See TORQUE SPECIFICATIONS. Connect CMP sensor connector.

Scheme 18

1. CKP sensor is located lower right side of cylinder block. Raise and support vehicle. Disconnect sensor harness connector. Remove sensor mounting bolt.
2. Using 2 screwdrivers, carefully pry sensor from engine block. Remove sensor. If reusing sensor, inspect "O" ring and replace as necessary.

Lightly oil sensor "O" ring. Push sensor into engine block using a slight rocking action. Install sensor mounting bolt and tighten to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

DISTRIBUTOR

Note. On all models, base ignition timing is not adjustable. Base ignition timing and timing advance are controlled by the PCM. If distributor is rotated or replaced, fuel system synchronization will be changed. To synchronize fuel system, see FUEL SYSTEM SYNCHRONIZATION in appropriate articles; For R2500 see ADJUSTMENTS - 8.0L , for R3500 see ADJUSTMENTS - 8.0L .

1. Disconnect negative battery cable. Remove air cleaner assembly. Remove distributor cap. Rotate crankshaft clockwise until piston No. 1 is at Top Dead Center (TDC) of compression stroke. Ensure timing marks are aligned.
2. Scribe a mark on distributor and adjacent component to indicate rotor and distributor housing position for installation reference.
3. Disconnect distributor harness connector. Remove distributor hold-down bolt. Slowly lift distributor straight up and remove distributor from engine. Note removed position of rotor during distributor removal for installation reference.

Distributor overhaul procedures are not available from manufacturer.

1. Clean distributor mounting hole area. Install new distributor-to-engine block gasket. Ensure piston No. 1 is at TDC of compression stroke. Carefully lower distributor into engine, engaging distributor shaft with slot in distributor oil pump drive gear.
2. Ensure distributor rotor aligns with spark plug wire position No. 1 on distributor cap and distributor housing reference marks made during removal procedure.
3. Install distributor cap. Install hold-down bolt and tighten to specification. See TORQUE SPECIFICATIONS. Connect distributor wiring harness connector. If factory replacement distributor was installed, remove alignment pin. Synchronize fuel system, see FUEL SYSTEM SYNCHRONIZATION in articles; For R2500 see «ADJUSTMENTS - 8.0L»(/dodge/pickup-r2500/1997-1998/remont/adjustments/#engine-controls-adjustments-80l-r2500) , for R3500 see «ADJUSTMENTS - 8.0L»(/dodge/pickup-r2500/1997-1998/remont/adjustments/#engine-controls-adjustments-80l-r3500) .

FUEL SYSTEM PRESSURE RELEASE

With Fuel Pressure Test Port

1. Disconnect negative battery cable. Slowly open fuel tank cap to release fuel tank pressure. Remove protective cap from pressure test port on fuel rail.
2. Obtain fuel pressure gauge and hose assembly from Fuel Pressure Gauge Tool Set (5069). Remove gauge from hose. Place gauge end of hose in approved gasoline container. Place shop towel under test port.
3. Screw other end of hose onto fuel pressure test port. Release fuel pressure. After pressure is released, remove hose from test port. Install protective cap on pressure test port.

Without Fuel Pressure Test Port

1. Remove fuel pump relay from Power Distribution Center (PDC). PDC is located near battery in left front corner of engine compartment.
2. Start and run engine until it stalls. Attempt to start engine until it will no longer run. Turn ignition off. Disconnect any fuel injector connector. CAUTION: Supplying power to fuel injector for more than 4 seconds will permanently damage injector.
3. Connect a jumper wire between either terminal of fuel injector and positive battery terminal. Connect one end of a second jumper wire to remaining fuel injector terminal. Momentarily touch other end of jumper wire to negative battery terminal.
4. Place shop towel under quick connect fitting at fuel rail. Disconnect fuel quick-connect fitting. After pressure is released, install fuel pump relay. If a Diagnostic Trouble Code (DTC) sets due to removal of fuel pump relay, clear DTC.

Removal (Single-Tab Type)

1. Release fuel pressure from fuel system. See FUEL SYSTEM PRESSURE RELEASE. Ensure area around fuel line is clean.
2. Cover fuel line with shop towel, as some residual fuel pressure may exist. Press release tab on side of quick-connect fitting. (Scheme 19) Using a screwdriver, pry up on pull tab. Raise pull tab until it separates form quick-connect fitting.

1. Clean and lightly lubricate quick-connect fitting with clean engine oil. Insert quick-connect fitting into fuel tube of fuel system component until built-on stop on fuel tube of component rests against back of fitting.
2. Using a new pull tab, push tab down until it locks into place. Pull on quick-connect fitting and fuel tube of component to verify pull tab is locked in place. Start engine and check for fuel leaks.

Scheme 19

Removal (Dual-Tab Type)

1. Release fuel pressure from fuel system. See FUEL SYSTEM PRESSURE RELEASE. Ensure area around fuel line is clean.
2. Cover fuel line with shop towel, as some residual fuel pressure may exist. Squeeze retaining tabs together on fuel quick-connect fitting. Pull fuel line quick-connect fitting from fuel tube of component. (Scheme 20)

1. Clean and lightly lubricate quick-connect fitting with clean engine oil. Insert quick-connect fitting into fuel tube of fuel system component until click sound is heard. Ensure retaining tabs are fully seated and visible in openings on the side of quick-connect fitting.
2. Pull on quick-connect fitting and fuel tube of component to verify locked position. Start engine and check for fuel leaks.

Scheme 20

Removal (Plastic Retainer Ring Type)

1. Release fuel pressure from fuel system. See FUEL SYSTEM PRESSURE RELEASE. Ensure area around fuel line is clean.
2. Cover fuel line with shop towel, as some residual fuel pressure may exist. Firmly push disconnect fitting toward the fuel line while pushing plastic retainer ring evenly into disconnect fitting. (Scheme 21) With plastic retainer ring fully depressed, pull quick-connect fitting from fuel line.
3. Inspect components for damage. If disconnect fitting is damaged, entire assembly must be replaced.

Ensure fuel line and quick-connect fitting are clean. Lubricate fuel line and quick-connect fitting with clean engine oil. Install disconnect fitting on fuel line until click sound is heard. Pull on fuel line and quick-connect fitting to ensure components are properly locked together. Start engine and check for leaks.

Scheme 21

Release fuel pressure from fuel system. See FUEL SYSTEM PRESSURE RELEASE. Remove air cleaner assembly. Ensure area around fuel line is clean. Insert Fuel Line Remover (OTC 7660) into fuel line and pull fuel line from fuel rail.

Ensure fuel line and fuel rail fitting are clean. Lubricate fuel line and fuel rail fitting with clean engine oil. Insert fuel line into fuel rail. Pull on fuel line to ensure fuel line and fuel rail are properly locked together. Start engine and check for leaks.

FUEL FILTER

Note. Separate frame mounted fuel filter is not used.

A combination fuel pressure regulator and fuel filter unit is used. Fuel pressure regulator/fuel filter is pressed into a rubber grommet located on top of fuel pump module. Fuel pressure regulator/fuel filter is not serviced separately. If fuel pressure regulator/fuel filter is defective, replace fuel pump module. See FUEL PUMP MODULE.

Fuel level sensor is part of fuel pump module and is not serviced separately. If fuel level sensor is defective, replace fuel pump module. See FUEL PUMP MODULE.

Fuel pressure regulator is part of fuel pump module and is not serviced separately. If pressure regulator is defective, replace fuel pump module. See FUEL PUMP MODULE.

Drain and remove fuel tank. See FUEL TANK. Fuel pump module lock nut is threaded onto fuel tank. Using Lock Nut Remover (6856), remove fuel pump module lock nut. Remove fuel pump module. To install, reverse removal procedure. Ensure new gasket is installed. Tighten lock nut to specification. See TORQUE SPECIFICATIONS.

1. Remove fuel filler cap to release fuel tank pressure. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Raise vehicle on hoist.
2. Drain fuel into an approved gasoline storage container. If fuel pump operates, fuel can be drained through fuel supply hose. If fuel pump does not operate but fuel level in tank is below fuel filler hose, fuel can be siphoned through fuel filler hose. Disconnect hose from filler neck. If fuel tank is full and fuel pump does not operate, drain fuel from filler neck.
3. To drain fuel from filler neck, support fuel tank using transmission jack. Loosen fuel tank mounting straps with passenger-side strap loosened more than driver-side strap. Lower tank slightly. Loosen filler neck to filler hose clamp. Slide clamp back on hose. To minimize fuel spill, wrap shop towels around filler hose. Disconnect filler hose from filler neck. Drain fuel tank through filler hose.
4. Disconnect all vent hoses and filler hose. Place a transmission jack under center of fuel tank, and apply slight pressure. Remove fuel tank retaining straps. Lower tank on transmission jack far enough to access fuel pump module connectors. Disconnect fuel tubes and fuel gauge sending unit connections from fuel pump module. Remove ground strap (if equipped). Remove fuel tank.

1. Place fuel tank on top of transmission jack, and raise it high enough to connect fuel tubes and fuel gauge wire to fuel pump module. Raise tank into position. Install ground strap (if equipped).
2. Install fuel tank mounting straps and nuts. Tighten mounting strap nuts to specification. See TORQUE SPECIFICATIONS. Remove transmission jack.
3. Connect vent hoses, filler tube and drain tube cap. Install new hose clamps, and tighten clamps securely. Connect fuel line if disconnected earlier. Refill tank, and inspect all hoses and lines for leaks. Reconnect negative battery cable. Pressurize system, and check for leaks.

1. Disconnect negative battery cable. Remove air cleaner housing and air tube. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove throttle body. See THROTTLE BODY.
2. Remove ignition coil pack. Remove generator and A/C braces. Remove upper intake plenum. Disconnect fuel injector wiring connectors (injector connectors are numerically tagged for installation reference). Disconnect fuel line at fuel rail. See FUEL LINE AT FUEL RAIL. Remove fuel rail mounting bolts.
3. Gently rock and pull on left fuel rail and then right fuel rail until injectors start to clear intake manifold. Repeat procedure until all injectors clear intake manifold. Remove fuel rail with injectors attached. Remove injector-to-fuel rail clips. Remove injectors.

1. Lightly lubricate injector "O" rings with clean engine oil. Install injectors and clips into fuel rail receiver cups. Ensure injectors and clips are fully seated.
2. Position fuel rail/injector assembly on intake manifold openings. Using care not to tear "O" rings, guide each injector into intake manifold. Push right and then left fuel rail down until injectors are bottomed on injector shoulder.
3. To complete installation, reverse removal procedure. Connect negative battery cable. Start engine and check for leaks.

1. Disconnect negative battery cable. Remove air cleaner assembly. Remove all control cables from throttle body (lever) arm. Disconnect wiring connectors as necessary.
2. Disconnect vacuum hose from throttle body. Remove 4 throttle body mounting bolts. Remove throttle body and gasket. To install, reverse removal procedure. Tighten throttle body bolts to specification.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• ADJUSTMENTS - 8.0L
• ADJUSTMENTS - 8.0L