SPECIFICATIONS
FUEL INJECTOR FIRING ORDER - DIESEL
1±5±3±6±2±4
TORQUE - FUEL SYSTEM - DIESEL ENGINE
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Accelerator Pedal Bracket Mounting 12 - 105
Accelerator Pedal Position Sensor
Bracket-to-Battery Tray Bolts3-30
Crankshaft Position Sensor 9 80
Camshaft Position Sensor 9 - 80
Engine Coolant Temperature Sensor 18 15 160
Rear Engine Lift Bracket Bolts 77 56 -
Fuel Connector Nut at Cylinder Head 50 37 -
Fuel Filler Hose Clamp at Tank 3 - 30
Fuel Filler Housing-to-Body Screws 2 - 17
Fuel Filter Lid 34 25 -
Fuel Filter Drain Valve Screws 1.5 - 14
Fuel Heater Element Screws 1.5 - 14
Fuel Pump Module Lock Ring 54 40 -
Fuel Line Banjo Fitting Bolts 24 18 -
Fuel Line Fittings (High-Pressure - Pump
to Rail)37 27 -
Fuel Line Fittings (High-Pressure -
Cylinder head to Rail)30 22 -
Bracket Over #6 Fuel Line (Bolts) 43 32 -
Fuel Injector Solenoid Nuts 1.25 - 11
Fuel Injection Pump-to-Gear Shaft Nut 105 77 -
Fuel Injection Pump Mounting Nuts 24 18 -
Fuel Line Support Clamps (High-
Pressure)24 18 -
Fuel Pressure Sensor 70 52 -
Fuel Pressure Limiting Valve (Banjo Bolt) 24 17 -
Fuel Pressure Limiting Valve (In Fuel
Rail)70 52 -
Fuel Rail Mounting Bolts 24 18 200
Fuel Tank Mounting Straps 41 30 -
Map Sensor Mounting Screws 1 - 9
ECM-to-Engine Bracket Mounting Bolts 24 18 -
ECM Electrical Harness Connector 3 - 27
Water-In-Fuel Sensor 4.5 - 39
14 - 48 FUEL DELIVERY - DIESELDR
FUEL DELIVERY - DIESEL (Continued)
INSTALLATION
CAUTION: Whenever the fuel tank module is ser-
viced, the rubber gasket must be replaced.
(1) Thoroughly clean locknut and locknut threads
at top of tank.(2) Using new gasket, carefully position fuel tank
module into opening in fuel tank.
(3) Position locknut over top of fuel tank module.
Install locknut finger tight.
(4) When looking down at tank from drivers side of
tank, the fuel line connectors and fuel gauge electri-
cal connector should all be pointed to drivers side of
vehicle. Rotate and align if necessary before tighten-
ing locknut.This step must be performed to pre-
vent the module's float from contacting side of
fuel tank.
(5) Tighten locknut to 24 - 44 N´m (18 - 32 ft. lbs.)
torque.
(6) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
FUEL TRANSFER PUMP
DESCRIPTION
The fuel transfer pump (fuel lift pump) is attached
to the rear of the fuel filter/water separator housing.
The 12±volt electric pump is operated and controlled
by the Engine Control Module (ECM).
OPERATION
The purpose of the fuel transfer pump is to supply
(transfer) a low-pressure fuel source:fromthe fuel
tank,throughthe fuel filter/water separator andto
the fuel injection pump. Here, the low-pressure is
raised to a high-pressure by the fuel injection pump
for operation of the high-pressure fuel injectors.
Check valves within the pump, control direction of
fuel flow and prevent fuel bleed-back during engine
shut down.
Maximum current flow to the pump is 5 amperes.
With the engine running, the pump has a 100 per-
cent duty-cycle.
The transfer pump is self-priming: When the key is
first turned on (without cranking engine), the pump
will operate for approximately 2 seconds and then
shut off. The pump will also operate for up to 25 sec-
onds after the starter is engaged, and then disen-
gaged and the engine is not running. The pump
shuts off immediately if the key is on and the engine
stops running.
The fuel volume of the transfer pump will always
provide more fuel than the fuel injection pump
requires. Excess fuel is returned from the injection
pump through an overflow valve, and then back to
the fuel tank.
REMOVAL
The fuel transfer pump (fuel lift pump) is attached
to the rear of the fuel filter/water separator housing
(Fig. 23).
Fig. 21 FUEL TANK MODULE - DIESEL
1 - TOP OF FUEL TANK
2 - AUX. FITTING
3 - ELEC. CONNECTOR
4 - FUEL TANK MODULE (TOP)
5 - LOCKNUT
6 - FUEL SUPPLY LINE
7 - FUEL RETURN LINE
Fig. 22 LOCKNUT REMOVAL/INSTALLATION -
TYPICAL MODULE
1 - SPECIAL TOOL 6856
2 - LOCKNUT
14 - 64 FUEL DELIVERY - DIESELDR
FUEL TANK MODULE (Continued)
FUEL INJECTION - DIESEL
TABLE OF CONTENTS
page page
ACCELERATOR PEDAL POSITION SENSOR
DESCRIPTION.........................68
OPERATION...........................68
REMOVAL.............................68
INSTALLATION.........................71
CAMSHAFT POSITION SENSOR
DESCRIPTION.........................71
OPERATION...........................71
REMOVAL.............................72
INSTALLATION.........................72
CRANKSHAFT POSITION SENSOR
DESCRIPTION.........................72
OPERATION...........................72
REMOVAL.............................73
INSTALLATION.........................73
FUEL CONTROL ACTUATOR
DESCRIPTION.........................74
OPERATION...........................74
REMOVAL.............................74
FUEL INJECTOR
DESCRIPTION.........................74
OPERATION...........................74
REMOVAL.............................75
INSTALLATION.........................77
FUEL INJECTOR RAIL
DESCRIPTION.........................78
OPERATION...........................78
REMOVAL.............................78
INSTALLATION.........................78INLET AIR TEMPERATURE SENSOR/
PRESSURE SENSOR
DESCRIPTION.........................79
OPERATION...........................79
REMOVAL.............................79
INSTALLATION.........................79
INTAKE AIR HEATER
DESCRIPTION.........................80
OPERATION...........................80
REMOVAL.............................80
INSTALLATION.........................80
INTAKE AIR HEATER RELAY
DESCRIPTION.........................82
OPERATION...........................82
REMOVAL.............................82
INSTALLATION.........................82
INTAKE AIR TEMPERATURE SENSOR/MAP
SENSOR
DESCRIPTION.........................82
OPERATION...........................82
REMOVAL.............................82
INSTALLATION.........................82
MAP SENSOR
DESCRIPTION.........................83
THROTTLE CONTROL CABLE
REMOVAL.............................83
INSTALLATION.........................84
PTO SWITCH
DESCRIPTION.........................85
OPERATION...........................85
ACCELERATOR PEDAL
POSITION SENSOR
DESCRIPTION
Engine Mounted Sensor:The APPS assembly is
located at the top-left-front of the engine. A plastic
cover is used to cover the assembly. The actual sen-
sor is located behind its mounting bracket.
Battery Tray Mounted Sensor:The Accelerator
Pedal Position Sensor (APPS) assembly is located
under the vehicle battery tray. A cable connects the
assembly to the accelerator pedal. A plastic cover
with a movable door is used to cover the assembly.
OPERATION
Engine Mounted Sensor:The Accelerator Pedal
Position Sensor (APPS) is a linear potentiometer. Itprovides the Engine Control Module (ECM) with a
DC voltage signal proportional to the angle, or posi-
tion of the accelerator pedal.
Battery Tray Mounted Sensor:The APPS pro-
vides the ECM with two DC voltage signals which
change as the position of the accelerator changes.
One of the DC voltage signals will be half the voltage
of the other signal.
REMOVAL
Engine Mounted Sensor :
The APPS is serviced (replaced) as one assembly
including the lever, brackets and sensor. The APPS is
calibrated to its mounting bracket. The APPS assem-
bly is located at left-front of engine below plastic
cable/lever/linkage cover (Fig. 1).
14 - 68 FUEL INJECTION - DIESELDR
INSTALLATION
Engine Mounted Sensor :
The APPS is serviced (replaced) as one assembly
including the lever, brackets and sensor. The APPS is
calibrated to its mounting bracket.
(1) Snap electrical connector into bottom of sensor.
(2) Position APPS assembly to engine and install 6
bolts. Tighten bolts to 24 N´m (18 ft. lbs.) torque.
(3) Connect wiring harness clip at bottom of
bracket.
(4) Refer to Group 21, Transmission for transmis-
sion control cable installation procedures.
(5) Install speed control cable into mounting
bracket. Be sure pinch tabs have secured cable.
(6) Install throttle cable into mounting bracket. Be
sure pinch tabs have secured cable.
(7) Connect throttle cable at lever (snaps on).
(8) Connect speed control cable to lever by pushing
cable connector rearward onto lever pin while hold-
ing lever forward.
(9) Install cable cover.
(10) Connect both negative battery cables to both
batteries.
(11) If necessary, use DRB IIItScan Tool to erase
any Diagnostic Trouble Codes (DTC's) from ECM.Battery Tray Mounted Sensor :
(1) Install Accelerator Pedal Position Sensor
(APPS) cable to accelerator pedal. Refer to Accelera-
tor Pedal Removal / Installation.
(2) Connect electrical connector to APPS.
(3) If necessary, connect cable to APPS lever ball
socket (snaps on).
(4) Snap APPS cable cover closed.
(5) Position APPS assembly to bottom of battery
tray and install 3 bolts. Refer to Torque Specifica-
tions.
(6) Install wheelhouse liner. Refer to Body.
(7) Perform the following procedure:
(a) Connect negative battery cables to both bat-
teries.
(b) Turn key switch ON, but do not crank
engine.
(c) Leave key switch ON for a minimum of 10
seconds. This will allow ECM to learn electrical
parameters.
(8) If necessary, use DRB IIItScan Tool to erase
any Diagnostic Trouble Codes (DTC's) from ECM.
CAMSHAFT POSITION
SENSOR
DESCRIPTION
The Camshaft Position Sensor (CMP) on the 5.9L
diesel engine is located below the fuel injection
pump. It is bolted to the back of the timing gear
housing.
OPERATION
The diesel Camshaft Position Sensor (CMP) con-
tains a hall effect device. A rotating target wheel
(tonewheel) for the CMP is located on the camshaft
gear. This hall effect device detects notches located
on the back side of the camshaft gear. As the cam-
shaft gear rotates, the notches pass the tip of the
CMP.
When the leading edge of the notch passes the tip
of the CMP, the following occurs: The interruption of
magnetic field causes the voltage to switch high
resulting in a signal of approximately 5 volts.
When the trailing edge of the notch passes the tip
of the CMP, the following occurs: The change of the
magnetic field causes the signal voltage to switch low
to 0 volts.
The CMP (Fig. 8) provides a signal to the Engine
Control Module (ECM) at all times when the engine
is running. The ECM uses the CMP information pri-
marily on engine start-up. Once the engine is run-
ning, the ECM uses the CMP as a backup sensor for
engine speed. The Crankshaft Position Sensor (CKP)
Fig. 7 APPS CABLE (OFF ENGINE MOUNTING)
1 - APPS LEVER
2 - BALL SOCKET
3 - SWING-DOWN DOOR
4 - CABLE CLIP
5 - CABLE
DRFUEL INJECTION - DIESEL 14 - 71
ACCELERATOR PEDAL POSITION SENSOR (Continued)
is the primary engine speed indicator for the engine
after the engine is running.
REMOVAL
The Camshaft Position Sensor (CMP) on the 5.9L
diesel engine is located below the fuel injection
pump. It is bolted to the back of the timing gear
housing (Fig. 9).
(1) Disconnect electrical connector at CMP sensor
(Fig. 9).
(2) Remove sensor mounting bolt.
(3) Carefully twist sensor from timing gear hous-
ing.
(4) Check condition of sensor o-ring.
INSTALLATION
(1) Clean out machined hole in back of timing gear
housing (cover).
(2) Apply a small amount of engine oil to sensor
o-ring.
(3) Install sensor into timing gear housing (cover)
with a slight rocking action. Do not twist sensor into
position as damage to o-ring may result.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to back of timingchain housing (cover). If sensor is not flush, dam-
age to sensor mounting tang may result.
(4) Install mounting bolt and tighten. Refer to
Torque Specifications.
(5) Connect electrical connector to sensor.
CRANKSHAFT POSITION
SENSOR
DESCRIPTION
The Crankshaft Position Sensor (CKP) on the die-
sel engine is attached at the front / left side of the
engine next to the engine harmonic balancer (crank-
shaft damper).
OPERATION
The Crankshaft Position Sensor (CKP) is the pri-
mary engine speed indicator for the engine after the
engine is running (Fig. 10). The CKP contains a hall
effect device. A rotating, notched target wheel (tone-
wheel) for the CKP is located on the engine harmonic
balancer (Fig. 11). This hall effect device detects
notches located on the tonewheel. As the tonewheel
rotates, the notches pass the tip of the CKP.
Fig. 8 5.9L DIESEL CMP
1 - CMP
2 - FUEL INJECTION PUMP (BOTTOM)
3 - ELECTRONIC CONTROL MODULE (ECM)
4 - ECM ELEC. CONNECTOR
5 - CMP ELEC. CONNECTOR
6 - CMP MOUNTING BOLT
7 - BACK OF TIMING GEAR HOUSING
Fig. 9 5.9L DIESEL CMP
1 - CMP
2 - FUEL INJECTION PUMP (BOTTOM)
3 - ELECTRONIC CONTROL MODULE (ECM)
4 - ECM ELEC. CONNECTOR
5 - CMP ELEC. CONNECTOR
6 - CMP MOUNTING BOLT
7 - BACK OF TIMING GEAR HOUSING
14 - 72 FUEL INJECTION - DIESELDR
CAMSHAFT POSITION SENSOR (Continued)
When the leading edge of the tonewheel notch
passes the tip of the CKP, the following occurs: The
interruption of magnetic field causes the voltage to
switch high resulting in a signal of approximately 5
volts.
When the trailing edge of the tonewheel notch
passes the tip of the CKP, the following occurs: The
change of the magnetic field causes the signal voltage
to switch low to 0 volts.
The Camshaft Position Sensor (CMP) also provides
a signal to the Engine Control Module (ECM) at all
times when the engine is running. The ECM uses
this CMP information primarily on engine start-up.
Once the engine is running, the ECM uses the CMP
as a backup sensor for engine speed.
REMOVAL
(1) Raise and support vehicle
(2) Disconnect electrical connector at CKP sensor
(Fig. 12).
(3) Remove 1 sensor mounting bolt.
(4) Remove CKP sensor.
INSTALLATION
(1) Position and install CKP sensor to engine.
(2) Install 1 sensor mounting bolt and tighten to 9
N´m (80 in. lbs.) torque.(3) Install electrical connector to CKP sensor (Fig.
12).
Fig. 10 5.9L DIESEL CKP
1 - ENGINE HARMONIC BALANCER
2 - FRONT OF TIMING GEAR COVER
3 - CKP MOUNTING BOLT
4 - ELEC. CONNECTOR
5 - CKP SENSOR
6 - NOTCHES
Fig. 11 CKP NOTCHED TONEWHEEL
1 - ENGINE HARMONIC BALANCER
2 - NOTCHED TONEWHEEL
3 - FRONT OF CRANKSHAFT
Fig. 12 5.9L DIESEL CKP
1 - ENGINE HARMONIC BALANCER
2 - FRONT OF TIMING GEAR COVER
3 - CKP MOUNTING BOLT
4 - ELEC. CONNECTOR
5 - CKP SENSOR
6 - NOTCHES
DRFUEL INJECTION - DIESEL 14 - 73
CRANKSHAFT POSITION SENSOR (Continued)
PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION.........................39
OPERATION...........................40
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 40
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER
STEERING PUMP - INITIAL OPERATION....40
STANDARD PROCEDURE - FLUSHING
POWER STEERING SYSTEM............40
REMOVAL
REMOVAL - GAS......................41
REMOVAL - DIESEL...................41
INSTALLATION
INSTALLATION - GAS..................42
INSTALLATION - DIESEL................42
SPECIFICATIONS
TORQUE CHART......................42
FLUID
DESCRIPTION.........................43
STANDARD PROCEDURE - POWER
STEERING FLUID LEVEL CHECKING......43
FLUID COOLER
REMOVAL.............................43
INSTALLATION.........................43
HOSES - I.F.S.
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER............................44
REMOVAL - PRESSURE HOSE...........44
REMOVAL - RETURN HOSE - RESERVOIR
TO COOLER.........................44INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER............................44
INSTALLATION - PRESSURE HOSE.......44
INSTALLATION - RETURN HOSE -
RESERVOIR TO COOLER...............44
HOSES - LINK/COIL
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER............................45
REMOVAL - PRESSURE HOSE...........45
REMOVAL - RETURN HOSE - RESERVOIR
TO COOLER.........................45
INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER............................45
INSTALLATION - PRESSURE HOSE.......45
INSTALLATION - RETURN HOSE -
RESERVOIR TO COOLER...............45
POWER STEERING PRESSURE SWITCH
DESCRIPTION.........................46
OPERATION...........................46
REMOVAL - 3.7L & 5.7L..................46
INSTALLATION - 3.7L & 5.7L...............46
PULLEY
REMOVAL.............................47
INSTALLATION.........................47
RESERVOIR
REMOVAL.............................47
INSTALLATION.........................47
PUMP
DESCRIPTION
CAUTION: MOPARTATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.The pump is connected to the steering gear via the
pressure hose and the return hose. The pump shaft
has a pressed-on pulley that is belt driven by the
crankshaft pulley.
All vehicles are equipped with a power steering
fluid cooler.
NOTE: Power steering pumps are not interchange-
able with pumps installed on other vehicles.
DRPUMP 19 - 39
PARK POWERFLOW
As the engine is running and the crankshaft is
rotating, the flexplate and torque converter, which
are also bolted to it, are all rotating in a clockwise
direction as viewed from the front of the engine. The
notched hub of the torque converter is connected to
the oil pump's internal gear, supplying the transmis-
sion with oil pressure. As the converter turns, it
turns the input shaft in a clockwise direction. As the
input shaft is rotating, the front clutch hub-rear
clutch retainer and all their associated parts are also
rotating, all being directly connected to the input
shaft. The power flow from the engine through the
front clutch hub and rear clutch retainer stops at the
rear clutch retainer. Therefore, no power flow to the
output shaft occurs because no clutches are applied.
The only mechanism in use at this time is the park-
ing sprag (Fig. 3), which locks the parking gear on
the output shaft to the transmission case.
NEUTRAL POWERFLOW
With the gear selector in the NEUTRAL position
(Fig. 4), the power flow of the transmission is essen-
tially the same as in the park position. The only
operational difference is that the parking sprag has
been disengaged, unlocking the output shaft from the
transmission case and allowing it to move freely.
Fig. 3 Park Powerflow
1 - PAWL ENGAGED FOR PARK
2 - PARK SPRAG
3 - OUTPUT SHAFT
Fig. 4 Neutral Powerflow
1 - PAWL DISENGAGED FOR NEUTRAL
2 - PARK SPRAG
3 - OUTPUT SHAFT
4 - CAM
5-PAWL
DRAUTOMATIC TRANSMISSION - 48RE 21 - 135
AUTOMATIC TRANSMISSION - 48RE (Continued)