1998 DODGE RAM 1500 Crank sensor

(11) Install air resonator tube to throttle body.
(12) Before starting engine, operate accelerator
pedal to check for any binding.
5.7L V-8
(1) Attach cable to Accelerator Pedal Position Sen-
sor (APPS). Refer to APPS Removal / Installation.
(2) Push cable housing into rubber grommet and
through opening in dash panel.
(3) From inside vehicle, install clip holding cable
to dashpanel (Fig. 1).
(4) From inside vehicle, slide throttle cable core
wire into opening in top of pedal arm.
(5) Push cable retainer (clip) into pedal arm open-
ing until it snaps in place.
(6) Before starting engine, operate accelerator
pedal to check for any binding.
(7) If necessary, use DRB IIItScan Tool to erase
any APPS Diagnostic Trouble Codes (DTC's) from
PCM.
THROTTLE POSITION SENSOR
DESCRIPTION
The 3-wire Throttle Position Sensor (TPS) is
mounted on the throttle body and is connected to the
throttle blade shaft.
The 5.7L V-8 engine does not use a separate TPS
on the throttle body.
OPERATION
The 5.7L V-8 engine does not use a separate Throt-
tle Position Sensor (TPS) on the throttle body.
The 3±wire TPS provides the Powertrain Control
Module (PCM) with an input signal (voltage) that
represents the throttle blade position of the throttle
body. The sensor is connected to the throttle blade
shaft. As the position of the throttle blade changes,
the output voltage of the TPS changes.
The PCM supplies approximately 5 volts to the
TPS. The TPS output voltage (input signal to the
PCM) represents the throttle blade position. The
PCM receives an input signal voltage from the TPS.
This will vary in an approximate range of from .26
volts at minimum throttle opening (idle), to 4.49 volts
at wide open throttle. Along with inputs from other
sensors, the PCM uses the TPS input to determine
current engine operating conditions. In response to
engine operating conditions, the PCM will adjust fuel
injector pulse width and ignition timing.The PCM needs to identify the actions and position
of the throttle blade at all times. This information is
needed to assist in performing the following calcula-
tions:
²Ignition timing advance
²Fuel injection pulse-width
²Idle (learned value or minimum TPS)
²Off-idle (0.06 volt)
²Wide Open Throttle (WOT) open loop (2.608
volts above learned idle voltage)
²Deceleration fuel lean out
²Fuel cutoff during cranking at WOT (2.608 volts
above learned idle voltage)
²A/C WOT cutoff (certain automatic transmis-
sions only)
REMOVAL
3.7L V6
The Throttle Position Sensor (TPS) is mounted to
the throttle body (Fig. 37), or (Fig. 38).
(1) Remove air resonator tube at throttle body.
(2) Disconnect TPS electrical connector.
(3) Remove 2 TPS mounting screws.
(4) Remove TPS.
Fig. 37 TPS LOCATION - 3.7L V-6
1 - THROTTLE POSITION SENSOR (TPS)
2 - MOUNTING SCREWS
3 - IDLE AIR CONTROL MOTOR (IAC)
4 - MOUNTING SCREWS
DRFUEL INJECTION - GAS 14 - 41
THROTTLE CONTROL CABLE (Continued)

Fig. 1 DIESEL FUEL SYSTEM COMPONENTS
1 - ENGINE COOLANT TEMPERATURE (ECT) SENSOR 14 - FUEL SUPPLY LINE (LOW-PRESSURE, TO ENGINE)
2 - THROTTLE LEVER BELLCRANK AND APPS (ACCELERATOR
PEDAL POSITION SENSOR)15 - FUEL RETURN LINE CONNECTION (TO FUEL TANK)
3 - INTAKE MANIFOLD AIR HEATER/ELEMENTS 16 - FUEL DRAIN TUBE
4 - FUEL PRESSURE SENSOR 17 - OIL PRESSURE SWITCH
5 - FUEL PRESSURE LIMITING VALVE 18 - ENGINE CONTROL MODULE (ECM)
6 - HIGH-PRESSURE FUEL LINES 19 - FUEL INJECTION PUMP
7 - FUEL HEATER 20 - CRANKSHAFT POSITION (ENGINE SPEED) SENSOR
8 - HIGH-PRESSURE FUEL RAIL 21 - CAMSHAFT POSITION SENSOR (CMP)
9 - FUEL HEATER TEMPERATURE SENSOR (THERMOSTAT) 22 - FUEL CONTROL ACTUATOR (FCA)
10 - FUEL FILTER/WATER SEPARATOR 23 - CASCADE OVERFLOW VALVE
11 - FUEL TRANSFER (LIFT) PUMP
12 - FUEL DRAIN MANIFOLD (CYLINDER HEAD FUEL RETURN
LINE)
13 - DRAIN VALVE
14 - 46 FUEL DELIVERY - DIESELDR
FUEL DELIVERY - DIESEL (Continued)

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)

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)

STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-CoilsŸ, or equivalent. This repair con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-CoilŸ tap, or
equivalent, and installing a Heli-CoilŸ insert, or
equivalent, into the hole. This brings the hole back to
its original thread size.
Heli-CoilŸ, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
REMOVAL
NOTE: The overdrive unit can be removed and ser-
viced separately. It is not necessary to remove the
entire transmission assembly to perform overdrive
unit repairs.
(1) Disconnect battery negative cable.
(2) Raise vehicle.
(3) Remove the transfer case skid plate (Fig. 12), if
equipped.(4) Disconnect and lower or remove necessary
exhaust components.
(5) Remove engine-to-transmission struts.
(6) Remove starter motor. (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
(7) Disconnect and remove the crankshaft position
sensor. (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION/CRANKSHAFT POSITION SENSOR -
REMOVAL) Retain the sensor attaching bolts.
(8) If transmission is being removed for overhaul,
remove transmission oil pan, drain fluid and reinstall
pan.
(9) Remove torque converter access cover.
(10) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.
(11) Mark propeller shaft and axle yokes for
assembly alignment. Then disconnect and remove
propeller shaft. On4x4models, remove both propel-
ler shafts. (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(12) Disconnect wires from the transmission range
sensor and transmission solenoid connector.
(13) Disconnect gearshift cable (Fig. 13) from the
transmission.
Fig. 12 Transfer Case Skid Plate
1 - FRAME RAIL
2 - SKID PLATE
3 - BOLTS (6)
Fig. 13 Gearshift Cable At Transmission
1 - GEARSHIFT CABLE
2 - TRANSMISSION MANUAL LEVER
3 - CABLE SUPPORT BRACKET
21 - 158 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)