FUEL TRANSFER PUMP
Removal
1) Disconnect negative battery cables. Clean area around
transfer pump and fuel lines. Remove starter. Place a drain pan below
pump. Disconnect fuel line fitting at fuel supply line. Remove support
bracket bolt at top of pump. Remove banjo bolts at front and rear of
pump.
2) Disconnect pigtail harness electrical connector from main
engine wiring harness. Remove 3 pump bracket nuts. Remove fuel
transfer pump.
Installation
1) Install new gaskets to fuel supply line, support bracket,
and banjo bolt at rear of pump. Install banjo bolt finger tight.
Install new gaskets to fuel line and banjo bolt at front of pump.
Position 3 pump studs into pump mounting bracket and install 3 nuts
finger tight. Install support bracket bolt finger tight.
2) Tighten bolts and nuts evenly to specification. See TORQUE
SPECIFICATIONS. Reconnect electrical connectors. 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
CAUTION: High-pressure fuel lines must be clamped securely and routed
so they do not contact each other or any other components. DO
NOT weld or substitute high-pressure fuel lines. High
-pressure lines are same length and proper high-pressure fuel
line must be installed in specified area for proper engine
operation.
Removal
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.
Installation
To install, reverse removal procedure. Ensure all high-
pressure fuel line nuts are tightened to specification at fuel
injector and fuel injection pump before tightening clamp bolts to
specification. Bleed high-pressure fuel lines. See FUEL LINE BLEEDING
under FUEL SYSTEM.
OVERFLOW VALVE
Removal & Installation
1) Disconnect negative battery cables. Ensure area around
overflow valve is clean. Remove valve from pump and banjo fitting.
Discard gaskets.
2) To install, reverse removal procedure using NEW gaskets.
Tighten overflow valve to specification. See TORQUE SPECIFICATIONS.
EMISSION SYSTEMS & SUB-SYSTEMS
located in power distribution center at driver's side front corner of
engine compartment, near the battery. Automatic Shutdown (ASD) relay
may also be referred to as Auto Shutdown (ASD) relay.
Battery Temperature Sensor
Battery temperature sensor delivers input signal to
Powertrain Control Module (PCM) to indicate the battery temperature.
PCM uses battery temperature input to modify rate of output from the
charging system. Battery temperature sensor is snapped into battery
tray below driver's side battery.
Battery Voltage
Battery voltage input signal provides operating voltage to
Powertrain Control Module (PCM). This input signal keeps PCM memory
alive and informs PCM what generator output voltage is when engine is
running. PCM memory is used to store Diagnostic Trouble Codes (DTCs),
store APPS sensor voltages from previous key cycles and provide a
speed control adaptive memory.
Brake Switch
Brake switch delivers input signal to Powertrain Control
Module (PCM) to indicate when brakes are applied. PCM uses input
signal for controlling cruise control system and transmission torque
converter clutch operation on A/T models. Brake switch is located near
top of brake pedal and may also be referred to as brakelight switch.
CKP Sensor
Crankshaft Position (CKP) sensor delivers input signal (35
tooth wheel with gap) to Engine Control Module (ECM) to indicate
engine speed and crankshaft position. ECM uses CKP signal along with
other input signals for controlling injector firing sequence and
timing. Sensor is located below fuel transfer pump, on side of engine
block. See Fig. 2.
Cruise Control System Switches
Cruise control system functions, controlled by momentary
contact switches, are monitored through multiplexed input signal to
Powertrain Control Module (PCM). Resistance monitored at this input
signal, in conjunction with the length of time the PCM measures the
resistance, determines which switch feature has been selected.
Data Link Connector (DLC)
Data Link Connector (DLC) provides an input signal to
Powertrain Control Module (PCM) when using scan tool to retrieve
Diagnostic Trouble Codes (DTCs) from PCM. Input signal may also be
used when performing various tests on the PCM and electronic control
system. DLC is a 16-pin connector located at lower edge of driver's
side of instrument panel, just above accelerator pedal.
Fuel Level Sensor
The Powertrain Control Module (PCM) sends a 5-volt signal to
the fuel level sensor. The fuel level sensor will return a signal to
PCM. This signal is used for fuel gauge operation and to prevent
setting a false misfire or fuel system trouble codes. If fuel level is
less than 15 percent, PCM will not set code.
Ignition Sense
Ignition switch position input to Powertrain Control Module
(PCM). PCM uses input to determine proper output functions, including
cruise control, generator output, sensor supply and transmission
functions.
Transmission Speed Sensor (A/T Models)
Fuel pump is a positive displacement, immersible pump with a
permanent magnet electric motor. Fuel is drawn in through a separate
filter/strainer at bottom of fuel pump and pushed through filter to
fuel outlet line (to fuel injectors). Voltage to operate pump is
supplied from fuel pump relay. On some models, fuel pump relay is
activated by ASD relay.
Fuel pump module includes a combination fuel filter/fuel
pressure regulator, fuel pump reservoir, a separate in-tank fuel
filter, pressure relief/rollover valve, fuel gauge sending unit and
fuel supply line. See Fig. 3.
Fig. 3: Identifying Fuel Pump Module Components (Typical)
Courtesy of Chrysler Corp.
FUEL CONTROL
Fuel Injectors
Fuel injectors are electric solenoid valves controlled by
PCM. PCM determines when and length of time (pulse width) injectors
should operate by switching ground path on and off. During start-up,
battery voltage is supplied to injectors through ASD relay. On some
models, battery voltage is supplied by charging system once engine is
PCM also operates A/C compressor clutch (if A/C is requested)\
through A/C clutch relay. When engine reaches operating temperature,
vehicle will go into idle mode and PCM will begin monitoring HO2S
input and go into closed loop operation.
* Idle - When engine is at operating temperature, this is a
closed loop mode. In idle mode, PCM now adds HO2S signal to
array of inputs used in ENGINE WARM-UP mode. PCM maintains
correct air/fuel ratio by adjusting injector pulse width and
ignition timing. PCM also controls A/C clutch operation (if
A/C is requested).
* Cruise - When engine is at operating temperature, this is a
closed loop mode. Using information from A/C switch, battery
voltage, CKP sensor, ECT sensor, IAT sensor, MAP sensor and
CMP sensor. PCM also monitors A/C request and P/N switch (A/T
only), TP sensor and VSS signals for fuel calculation. PCM
monitors HO2S and adjusts air/fuel ratio as needed. PCM
controls engine idle speed through IAC motor. PCM controls
spark advance as necessary.
* Acceleration - This is an open loop mode. When PCM
recognizes an abrupt increase in throttle position or
manifold pressure as a demand for increased engine output, it
increases injector pulse width in response to increased fuel
demand. HO2S signals are ignored.
* Deceleration - This is an open loop mode when engine is at
operating temperature and under deceleration. When PCM
receives inputs signaling a closed throttle and an abrupt
decrease in manifold pressure, it reduces injector pulse
width to lean air/fuel mixture. Under certain RPM and closed
throttle position conditions, HO2S signals are ignored and
PCM cuts off fuel injection until idle speed is reached. PCM
also drives IAC motor for smooth transition to idle mode.
* Wide Open Throttle - This is an open loop mode. When PCM
senses wide open throttle, it grounds fuel injectors in
sequence, it ignores HO2S input and it controls pulse width
to supply a pre-determined amount of additional fuel. PCM
also adjusts spark advance and disengages A/C clutch for
approximately 15 seconds.
* Ignition Switch Off - This is an open loop mode. PCM drives
IAC motor into position in anticipation of next start-up. All
outputs are turned off, no inputs are monitored and PCM shuts
down.
Sequential Fuel Injection (SFI)
Individual, electrically pulsed injectors (one per cylinder)
are located in intake manifold runners. These injectors are next to
intake valves in intake manifold. PCM controls injection timing based
on crankshaft position signal input. PCM regulates air/fuel mixture by
length of time injector stays open (pulse width) based on inputs from
HO2S, ECT sensor, MAP and other sensors.
IDLE SPEED
NOTE: DO NOT attempt to correct a high idle speed condition by
turning factory sealed throttle body throttle plate set
screw. This will not change idle speed of warm engine, but
may cause cold start problems due to restricted airflow.
Idle Air Control (IAC) Motor
IAC motor adjusts idle speed to compensate for engine load
and ambient temperature by adjusting amount of air flowing through by-
pass in back of throttle body. PCM uses ECT sensor, VSS, TP sensor and
Courtesy of Chrysler Corp.
Installation
1) To install, reverse removal procedure. Ensure torque
converter is fully seated in transmission by measuring distance from
cylinder block surface on transmission housing to front edge on torque
converter bolt lug on front of torque converter. Distance should be .
50" (12.7 mm) if torque converter is fully seated.
CAUTION: Proper length torque converter bolts must be used. If
replacing any torque converter bolts, ensure proper length
bolt is used.
2) Tighten bolt/nuts to specification. See TORQUE
SPECIFICATIONS. Ensure reference mark on torque converter and
flexplate, and drive shaft flanges are aligned. Adjust shift cable or
linkage, throttle valve cable and transfer case shift linkage if
necessary. See AUTOMATIC TRANSMISSION - TRUCKS & RWD VANS article.
3) Use NEW "O" ring when installing dipstick tube. Before
installing oil cooler lines on transmission, ensure all fittings are
clean. Install oil cooler line into quick-disconnect fitting. Push oil
cooler line inward until a click is heard. Pull on oil cooler line to
ensure oil cooler line is locked in place. Fill transmission with
Mopar ATF Plus Type 7176.
RAM PICKUP
Removal
1) Disconnect negative battery cable. Raise and support
vehicle. Disconnect and remove necessary skid plates and exhaust
components for transmission removal. Remove engine-to-transmission
struts (if equipped). These struts are located between front of
transmission and engine.
2) Ensure area around transmission oil cooler lines fitting
are clean. Disengage retainer on quick-disconnect cooler line fitting.
Pull cooler line from transmission oil cooler. Remove starter.
CAUTION: On 3.9L, 5.2L and 5.9L gasoline models, crankshaft position
sensor must be removed from transmission housing before
removing transmission to prevent damage to crankshaft
position sensor.
3) On 3.9L, 5.2L and 5.9L gasoline models, disconnect
electrical connector for crankshaft position sensor. Crankshaft
position sensor is mounted on passenger's side of transmission
housing. See Fig. 2.
4) Remove crankshaft position sensor bolts. Remove crankshaft
position sensor from transmission housing. Remove dipstick, dipstick
tube and "O" ring from transmission.
5) Remove torque converter cover. Place reference mark on
flexplate and torque converter for installation reference. Rotate
crankshaft clockwise and remove torque converter bolts.
6) Place reference mark on drive shaft flanges for
installation reference. Remove drive shaft from transmission. On 4WD
models, disconnect drive shaft from transfer case. Disconnect shift
rod for transfer case from transfer case shift lever.
7) On all models, disconnect necessary control cables, wiring
harnesses, and shift linkage from transmission. Support rear of engine
with jack stand. Using transmission jack, slightly raise transmission
to release pressure from rear mount and rear crossmember.
8) Remove bolts securing rear support and rear mount to
transmission and rear crossmember. Raise transmission slightly. Slide
exhaust hanger arm from bracket on rear support. Remove rear support
and rear mount.
9) Remove rear crossmember located below the transmission. On
4WD models, disconnect electrical connectors from transfer case. On
all models, remove transmission-to-cylinder block bolts. Slide
transmission rearward from dowels on cylinder block.
10) Install "C" clamp on edge of transmission housing to hold
torque converter in place. Lower transmission and remove transmission
from vehicle.
Installation
1) To install, reverse removal procedure. Ensure torque
converter is fully seated in transmission by measuring distance from
cylinder block surface on transmission housing to front edge on torque
converter bolt lug on front of torque converter. Distance should be .
50" (12.7 mm) if torque converter is fully seated.
CAUTION: Proper length torque converter bolts must be used. If
replacing any torque converter bolts, consult parts
department to ensure proper length bolt is used.
2) Tighten bolt/nuts to specification. See TORQUE
SPECIFICATIONS. Ensure reference mark on torque converter and
flexplate, and drive shaft flanges are aligned. Adjust shift linkage,
throttle valve cable and transfer case shift linkage if necessary. See
AUTOMATIC TRANSMISSION - TRUCKS & RWD VANS article.
3) Use NEW "O" ring when installing dipstick tube. Before
installing oil cooler lines on transmission, ensure all fittings are
clean. Install oil cooler line into quick-disconnect fitting. Push oil
cooler line inward until a click is heard. Pull on oil cooler line to
ensure oil cooler line is locked in place. Fill transmission with
Mopar ATF Plus Type 7176.
RAM VAN/WAGON
Removal
1) Disconnect negative battery cable. Raise and support
vehicle. Remove engine-to-transmission struts. These struts are
located between front of transmission and engine.
2) Remove starter and oil cooler line bracket. Ensure area
around transmission oil cooler lines fitting are clean. Disengage
retainer on quick-disconnect cooler line fitting. Pull cooler line
from transmission oil cooler.
CAUTION: Crankshaft position sensor must be removed from transmission
housing before removing transmission to prevent damage to
crankshaft position sensor.
3) Disconnect electrical connector for crankshaft position
sensor. Crankshaft position sensor is mounted on passenger's side of
transmission housing. See Fig. 2.
4) Remove crankshaft position sensor bolts. Remove crankshaft
position sensor from transmission housing. Remove dipstick, dipstick
tube and "O" ring from transmission.
5) Remove torque converter cover. Place reference mark on
flexplate and torque converter for installation reference. Rotate
crankshaft clockwise and remove torque converter bolts.
6) Place reference mark on drive shaft yokes for installation
reference. Remove drive shaft from transmission. Disconnect necessary
wiring harnesses and control cables from transmission. Support rear of
engine with hoist. Using transmission jack, slightly raise
transmission to release pressure from rear mount and crossmember.
7) Remove rear mount-to-rear crossmember bolts. Remove bolts
and rear crossmember located below the transmission. Remove engine oil
filter (if necessary). Remove transmission-to-cylinder block bolts.
Slide transmission rearward from dowels on cylinder block.
8) Install "C" clamp on edge of transmission housing to hold
torque converter in place. Lower transmission and remove transmission
from vehicle.
Installation
1) To install, reverse removal procedure. Ensure torque
converter is fully seated in transmission by measuring distance from
cylinder block surface on transmission housing to front edge on torque
converter bolt lug on front of torque converter. Distance should be .
50" (12.7 mm) if torque converter is fully seated.
CAUTION: Proper length torque converter bolts must be used. If
replacing any torque converter bolts, ensure proper length
bolt is used.
2) Ensure proper length torque converter bolts are used in
accordance with torque converter diameter and number of torque
converter bolt lugs on front of torque converter. See TORQUE CONVERTER
BOLT APPLICATION table.
TORQUE CONVERTER BOLT APPLICATION
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Torque Converter Diameter Bolt Length
In. (mm)\
9.50" (241.0 mm) 3-Bolt Lug Torque Converter ............ .46 (11.7\
)
9.50" (241.0 mm) 4-Bolt Lug Torque Converter ............ .52 (13.2\
)
10.00" (254.0 mm) 4-Bolt Lug Torque Converter ........... .52 (13.2\
)
10.75" (273.0 mm) 4-Bolt Lug Torque Converter ........... .44 (11.2\
)
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3) Tighten bolt/nuts to specification. See TORQUE
SPECIFICATIONS. Ensure reference mark on torque converter and
flexplate, and drive shaft yokes are aligned. Adjust shift cable and
throttle valve cable if necessary. See AUTOMATIC TRANSMISSION - TRUCKS
& RWD VANS article.
4) Use NEW "O" ring when installing dipstick tube. Before
installing oil cooler lines on transmission, ensure all fittings are
clean. Install oil cooler line into quick-disconnect fitting. Push oil
cooler line inward until a click is heard. Pull on oil cooler line to
ensure oil cooler line is locked in place. Fill transmission with
Mopar ATF Plus Type 7176.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (DAKOTA & DURANGO) \
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Application Ft. Lbs.
Crankshaft Position Sensor Bolt/Nut
2.5L ..................................................... 14 (19)\
3.9L, 5.2L & 5.9L ............................................ ( 1)
Front Drive Shaft Universal Joint Strap-To-Transfer
Case Flange Bolt ......................................... 20 (27)\
Rear Crossmember Bolt ...................................... 50 (68)\
Rear Drive Shaft Center Bearing-To-Crossmember Bolt ........ 50 (68)\
Rear Drive Shaft Universal Joint Strap-To-Rear
Axle Flange Bolt ......................................... 14 (19)\
Starter Bolt
2.5L ..................................................... 33 (45)\
vehicle is at normal riding height.
* Steering wheel must be centered with wheels in straight ahead
position. If required, shorten one tie rod adjusting sleeve
and lengthen opposite sleeve (equal amount of turns). See
Fig. 2.
* Wheel bearings should have the correct preload and lug nuts
must be tightened to manufacturer's specifications. Adjust
camber, caster and toe-in using this sequence. Follow
instructions of the alignment equipment manufacturer.
CAUTION: Do not attempt to correct alignment by straightening parts.
Damaged parts must be replaced.
Fig. 2: Adjusting Tie Rod Sleeves (Top View)
CAMBER
1) Camber is the tilting of the wheel, outward at either top
or bottom, as viewed from front of vehicle. See Fig. 3.
2) When wheels tilts outward at the top (from centerline of
vehicle), camber is positive. When wheels tilt inward at top, camber
is negative. Amount of tilt is measured in degrees from vertical.