Engine Controls - Remove/install/overhaul - 3.9l Dodge Ram Van B3500 B pre

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

1. Disconnect distributor pick-up connector from wiring harness connector. Remove splash shield (if equipped). Remove distributor cap. Rotate crankshaft until distributor rotor is pointing toward cylinder No. 1 terminal of distributor cap.
2. To indicate rotor and distributor housing position when reinstalling distributor, scribe mark on distributor or adjacent component as reference. Remove distributor hold-down nut. Carefully lift distributor from engine.

Information is not available.

Installation

1. Position distributor in engine. Ensure "O" ring is properly seated on distributor. Replace "O" ring if it is cracked or nicked. Carefully engage distributor drive with camshaft drive so that when distributor is installed properly, rotor aligns with reference mark on intake plenum.
2. Install distributor cap. Check all high tension wires for good connections. Install hold-down nut. Connect distributor lead wire at wiring harness connector.

Removal & Installation

Disconnect negative battery cable. Remove distributor cap. Disconnect camshaft position sensor connector from harness connector. Remove distributor rotor. Lift and remove sensor from distributor. To install, reverse removal procedure.

CRANKSHAFT POSITION SENSOR

Note. On some models, it may not be necessary to remove all components listed.

1. Remove spark plug cable loom and spark plug wires from mounting stud on rear of right valve cover. Disconnect hoses from EGR valve. Disconnect connector and hoses at EGR transducer.
2. Remove EGR valve. Disconnect connector at Oil Pressure Sending (OPS) unit. Using appropriate socket, remove OPS unit. Remove EGR tube. Disconnect crankshaft connector from harness connector. Remove crankshaft position sensor.

To install, reverse removal procedure. Replace all EGR valve and tube gaskets. Coat OPS unit threads with sealant before installing.

FUEL SYSTEM PRESSURE RELEASE

The fuel system is under constant fuel pressure (even with the engine off).

Scheme 12

3.9L/5.2L Engine

1. Disconnect negative battery cable.
2. Remove the fuel tank filler tube cap to release fuel tank pressure.
3. Remove protective cap from pressure test port on the fuel rail (Scheme 13)
4. Obtain the fuel pressure gauge/hose assembly from fuel pressure gauge tool set 5069. Remove the gauge from the hose.
5. Place one end of hose (gauge end) into an approved gasoline container.
6. Place a shop towel under the test port.
7. To release fuel pressure, screw the other end of hose onto the fuel pressure test port.
8. After fuel pressure has been released, remove the hose from the test port.
9. Install protective cap to fuel test port.

Removal - Fuel Filter Or Fuel Pressure Regulator

Refer to FUEL SYSTEM PRESSURE RELEASE .

The fuel filter/fuel pressure regulator is located on the top of fuel pump module (Scheme 14)

Fuel pump module removal is not necessary.

Scheme 13

1. Drain fuel tank and remove tank. Refer to «FUEL TANK»(/dodge/ram-van-b3500/b-pre-1995-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul-39l__fuel-tank).
2. The fuel filter/regulator is pressed into a rubber grommet. Remove by twisting and pulling straight up see scheme 4
3. Remove the snap ring retaining the convoluted tube (cover) to the filter/regulator see scheme 5 Slide the plastic tube down the fuel tube to clear the fuel tube clamp.
4. Gently cut the old fuel tube (line) clamp see scheme 6 taking care not to damage the plastic fuel tube. Remove and discard the old fuel tube clamp.
5. Remove the plastic fuel tube from the filter regulator by gently pulling downward. Remove filter/regulator from fuel pump module.

1. Install a new clamp over the plastic fuel tube.
2. Install filter/regulator to fuel tube. Rotate the filter/regulator in the fuel tube (line) until it is pointed to the drivers side of vehicle (Scheme 14)
3. Tighten line clamp to fuel line using special Hose Clamp Pliers number C-4124 or equivalent see scheme 7 Do not use conventional side cutters to tighten this type of clamp.
4. Slide the convoluted plastic tube (cover) up to the bottom of filter/regulator and install snap ring see scheme 5
5. Press the filter/regulator (by hand) into the rubber grommet. The assembly should be pointed to the drivers side of the vehicle (Scheme 14)
6. Install fuel tank. Refer to «FUEL TANK»(/dodge/ram-van-b3500/b-pre-1995-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul-39l__fuel-tank).
7. Check for leaks.

Drain and remove fuel tank. See FUEL TANK . Fuel pump module lock nut is threaded onto fuel tank. Remove fuel pump module lock nut. Remove pump. To install, reverse removal procedure. Ensure new gasket is installed.

FUEL TANK

The standard equipment fuel tank on all models is located between the left frame structure and the propeller shaft. This is forward of the rear axle see scheme 8 The tank is constructed of high density polyethylene.

Scheme 14

1. Remove fuel filler cap to release fuel tank pressure. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/dodge/ram-van-b3500/b-pre-1995-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul-39l__fuel-system-pressure-release) . Disconnect negative battery cable. Raise vehicle on hoist.
2. Drain fuel into an appropriate gasoline safety 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). Install fuel tank mounting straps and tighten mounting straps. On all models, remove transmission jack.
2. 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. Release fuel system pressure. Proceed to the «FUEL SYSTEM PRESSURE RELEASE»(/dodge/ram-van-b3500/b-pre-1995-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul-39l__fuel-system-pressure-release) . Disconnect negative battery cable. Remove air cleaner. Remove throttle body from intake manifold. Remove air conditioning compressor-to-intake manifold support bracket (if equipped).
2. Disconnect fuel injector wiring connectors (injector connectors are numerically tagged for installation reference). Remove vacuum line from fuel pressure regulator.
3. Disconnect intake manifold charge air temperature sensor connector. DO NOT remove sensor. Remove EVAP canister purge solenoid/bracket assembly from intake manifold. Disconnect 2 rear fuel rail fuel lines, and remove remaining fuel rail mounting bolts. CAUTION: The left and right fuel rails are replaced as an assembly. DO NOT attempt to separate rail halves at connecting hoses. Never attempt to install a clamping device of any kind to hose(s). When removing fuel rail assembly, be careful not to bend or kink connecting hoses.
4. Gently rock and pull on left fuel rail and then right fuel rail until injectors start to clear intake manifold. Repeat procedure until injectors clear intake manifold, and remove fuel rail with injectors attached. Remove injector-to-fuel rail clips. Remove injectors.

1. Lubricate injector "O" rings with a drop of clean engine oil. Install injectors and clips into fuel rail receiver cups. Ensure injectors and clips are fully seated. 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.
2. To complete installation, reverse removal procedure. Connect negative battery cable, and check for leaks.

1. Remove fuel rail. See «FUEL INJECTOR RAILS»(/dodge/ram-van-b3500/b-pre-1995-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul-39l) . Disconnect injector wiring connector from injector. Position fuel rail assembly so injectors are accessible.
2. Rotate and pull injector out of fuel rail (clip will remain on injector). Inspect injector "O" ring and clip for damage. Replace "O" ring if it is damaged. If injector is to be reused, install a protective cap on injector tip to prevent damage. Replace clip if it is damaged. Repeat for remaining injectors.

Lubricate "O" ring of each injector with a drop of clean engine oil to aid in installation. Install injector top end into fuel rail receiver cup. Be careful not to damage "O" ring during installation. Repeat for remaining injectors. Install wiring harness to injectors. Fasten wiring harness into wiring clips (if equipped).

Regulator is combined with fuel filter mounted in fuel pump module in fuel tank. Remove fuel tank. See FUEL TANK . Remove filter/regulator by twisting and pulling straight upward (DO NOT exceed 3 inches). Remove snap ring and pull down protective cover. Cut and remove fuel line clamp. Disconnect fuel line.

To install filter/regulator, reverse removal procedure. Use appropriate fuel clamp pliers to tighten fuel clamp. DO NOT use diagonal cutters to tighten clamp. Check for fuel leaks.

1. Oxygen sensor is mounted in exhaust pipe just below exhaust header. It is equipped with a permanent pigtail, which must be protected from damage when sensor is removed. Carefully disconnect engine harness from HO2S connector. DO NOT pull on sensor wiring when disconnecting sensor connector. Remove sensor using appropriate socket. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C).
2. Ensure sensor is free of contaminants; DO NOT use cleaning solvents. Use an 18 mm x 1.5 x 6E tap to clean threads in exhaust manifold. If installing original sensor, sensor threads must be coated with anti-seize compound. New HO2S is packaged with compound already on threads. To install, reverse removal procedure.

Removal & Installation (MFI)

1. Disconnect negative battery cable. Remove air cleaner components as necessary.
2. Remove throttle cable, speed control cables and transaxle linkage (if equipped). Disconnect wiring connectors for automatic idle speed motor and throttle position sensor. Disconnect vacuum hoses from throttle body.
3. Remove throttle body-to-intake manifold attaching nuts. Remove throttle body and gasket. To install, reverse removal procedure. Tighten throttle body attaching nuts.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• COMPUTER RELEARN PROCEDURES
• FUEL SYSTEM PRESSURE RELEASE
• FUEL TANK
• FUEL INJECTOR RAILS