2001 DODGE RAM harness

CYLINDER HEAD
DESCRIPTION
The cylinder head (Fig. 13) is constructed of cast
iron and is a one piece cross flow design with four
valves per cylinder. The arrangement of two intake
and two exhaust valves per cylinder allows for a cen-
trally located injector. The cylinder head also
includes an integral intake manifold, an integral
thermostat housing, and a longitudal fuel return
rifle, which exits at the rear of the head. The 24
valve design also includes integrally cast valve
guides and hardened intake and exhaust valve seat
inserts.
REMOVAL
(1) Disconnect battery negative cables.
(2) Raise vehicle on hoist.
(3) Drain engine coolant.
(4) Disconnect exhaust pipe from turbocharger
elbow (Fig. 14).
(5) Lower vehicle.
(6) Remove air cleaner housing and snorkel from
the vehicle. Cap off turbocharger air inlet to prevent
intrusion of dirt or foreign material.
(7) Disconnect cab heater core supply and return
hoses from the cylinder head and heater pipe.
(8) Disconnect turbocharger oil drain tube at rub-
ber hose connection. Cap off open ports to prevent
intrusion of dirt or foreign material.
(9) Disconnect turbocharger oil supply line at the
turbocharger end. Cap off open ports to prevent
intrusion of dirt or foreign material.
(10) Remove exhaust manifold-to-cylinder head
bolts and spacers. Remove exhaust manifold and tur-
bocharger from the vehicle as an assembly.
(11) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(12) Remove generator upper bracket.
(13) Disconnect radiator upper hose from the ther-
mostat housing.
(14) Disconnect the coolant temperature sensor
connector.
(15) Remove the engine harness to cylinder head
attaching bolt at front of head.
(16) Remove the engine harness ground fastener
at front of head below the thermostat housing.
Fig. 13 Cylinder Head and Gasket
1 - THERMOSTAT BORE
2 - INTAKE RUNNER
3 - CYLINDER HEAD
4 - CYLINDER HEAD GASKET
5 - CYLINDER BLOCK
Fig. 14 Exhaust Pipe-to-Turbocharger Elbow
1 - EXHAUST PIPE
2 - TURBOCHARGER EXHAUST PIPE
9 - 246 ENGINE 5.9L DIESELBR/BE

(17) Remove the throttle linkage cover (Fig. 15).
(18) Remove the six (6) accelerator pedal position
sensor assembly-to-cylinder head bracket bolts (Fig.
16) and secure the entire assembly out of the way.
Disconnect the APPS connector (Fig. 17).It is notnecessary to disconnect the cables from the
throttle control assembly.
(19) Remove the intake air grid heater wires from
the grid heater.
(20) Remove engine oil level indicator tube attach-
ing bolt from the air inlet housing.
(21) Remove the charge air cooler-to-air inlet hous-
ing pipe.
(22) Remove the air inlet housing and intake grid
heater from the intake manifold cover.
(23) Remove the engine lift bracket from the rear
of the cylinder head.
Fig. 15 Throttle Linkage Cover
1 - CABLE/LEVER/LINKAGE COVER
2 - PUSH UP LOWER TAB
3 - SCREWS/CLIPS (2)
4 - TAB PUSH HERE
Fig. 16 APPS Assembly
1 - LEVER
2 - MOUNTING BOLTS (6)
3 - WIRE HARNESS CLIP
4 - CALIBRATION SCREWS (NO ADJUSTMENT)
5 - APPS ASSEMBLY
Fig. 17 APPS Connector
1 - APPS
2-TAB
3 - PUSH FOR REMOVAL
4 - APPS CONNECTOR
Fig. 18 High-Pressure Lines at Cylinder Head
BR/BEENGINE 5.9L DIESEL 9 - 247
CYLINDER HEAD (Continued)

(e) Install the front line bundle (cyls. #1, 2, and
4) following the same procedure used for the rear
line bundle.
(f) Torque the connections at the cylinder head
first. Torque connections to 38 N´m (28 ft. lbs.).
(g) Torque the line connections at the injection
pump to 24 N´m (18 ft. lbs.).
(h) Install the injection line support bracket to
intake cover/cylinder head bolts and torque to 24
N´m (18 ft. lbs.).
(16) Install the engine lift bracket at the rear of
cylinder head. Torque to 77 N´m (57 ft. lbs.).
(17) Install the fuel filter to injection pump low
pressure line. Inspect and replace sealing washers if
necessary. Torque banjo bolts to 24 N´m (18 ft. lbs.).
(18) Using new gaskets, install the intake grid
heater and air inlet housing. Torque bolts to 24 N´m
(18 ft. lbs.).
(19) Connect the APPS connector (Fig. 17).
(20) Install the APPS assembly. to the cylinder
head bracket and torque bolts to 12 N´m (105 in.
lbs.).
(21) Install the throttle linkage cover (Fig. 15).
(22) Install the charge air cooler-to-air inlet hous-
ing duct assembly. Torque all clamps to 11 N´m (100
in. lbs.).
(23) Connect intake grid heater wires.
(24) Fasten engine harness to front of cylinder
head with bolt.
(25) Install engine harness ground wire and torque
bolt to 24 N´m (18 ft. lbs.).
(26) Connect engine coolant temperature sensor
connector.
(27) Connect radiator upper hose to thermostat
housing.
(28) Install generator upper bracket and torque
bolts to 41 N´m (31 ft. lbs.).
(29) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(30) Install exhaust manifold/turbocharger assem-
bly. and start all bolts/spacers by hand. Torque bolts
to 43 N´m (32 ft. lbs.).
(31) Connect turbocharger oil drain tube.
(32) Perform the turbocharger pre-lube procedure.
Refer to Group 11, Exhaust System and Turbo-
charger for the correct procedure.
(33) Connect the turbocharger oil supply line.
(34) Install air cleaner housing and duct.
(35) Raise vehicle on hoist.
(36) Install exhaust pipe to turbocharger elbow
(Fig. 14). Torque bolts to 34 N´m (25 ft. lbs.).
(37) Lower vehicle.
(38) Fill engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(39) Start engine and check for leaks.
Fig. 32 Rocker Arms and Pedestal Installation
1 - ROCKER ARM
2 - PEDESTAL
Fig. 33 Cylinder Head Cover Installation
1 - BOLT (5)
2 - GASKET
3 - ªTOP FRONTº
4 - ISOLATOR (5)
9 - 252 ENGINE 5.9L DIESELBR/BE
CYLINDER HEAD (Continued)

DIAGNOSIS AND TESTING - GAS ENGINE
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking
joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.6. Tighten exhaust manifold to
cylinder head bolts.
7. Catalytic converter rusted or
blown out.7. Replace catalytic converter assy.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
caution:
When servicing and replacing exhaust system components, disconnect the oxygen sensor connector(s).
Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.
DIAGNOSIS AND TESTING - DIESEL ENGINE
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking
joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.6. Tighten exhaust manifold to
cylinder head bolts.
7. Turbocharger mounting flange
cracked.7. Remove turbocharger and
inspect. (Refer to 11 - EXHAUST
SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER -
REMOVAL).
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
11 - 4 EXHAUST SYSTEMBR/BE
EXHAUST SYSTEM (Continued)

FRONT LOWER FASCIA
REMOVAL
(1) Open hood.
(2) Remove fasteners at side fender openings.
(3) Remove lower air dam.(Refer to 13 - FRAMES
& BUMPERS/BUMPERS/FRONT AIR DAM -
REMOVAL)
(4) Disengage clips attaching end of upper fascia to
bumper face bar (Fig. 5).
(5) Disengage clips attaching lower fascia to
bumper face bar.
(6) Separate lower fascia from bumper.
INSTALLATION
(1) Position lower fascia on bumper.
(2) Engage clips attaching lower fascia to bumper
face bar.
(3) Install lower air dam.(Refer to 13 - FRAMES &
BUMPERS/BUMPERS/FRONT AIR DAM - INSTAL-
LATION)
(4) Install fasteners at side fender openings.
FRONT FASCIAÐSPORT
REMOVAL
The fascia can be removed from the vehicle without
removing the bumper.
(1) Disconnect wire connectors from fog lamps.
(2) Remove screws attaching rearward edges of
fascia to outer bumper brackets (Fig. 7).
(3) Remove screws attaching bottom of air deflec-
tor.(4) Lift top of fascia upward to disengage from
retaining clips on front bumper.
(5) Pull fascia from front bumper and separate
from vehicle.
INSTALLATION
(1) Position fascia on front bumper.
(2) Engage fascia with retaining clips on front
bumper.
(3) Install screws attaching bottom of fascia to air
deflector.
(4) Align fascia and wheelhouse liners with outer
bumper brackets and install screws.
(5) Connect harness connectors to fog lamps.
FRONT BUMPER
REMOVAL
(1) Support front bumper on a suitable lifting
device.
(2) Remove bolts attaching front bumper outer
bracket to frame rail (Fig. 6).
(3) Remove nuts and stud plates attaching front
bumper to end of frame rail.
(4) Disengage wire connectors from fog lamps, if
equipped.
(5) Separate front bumper from vehicle.
Fig. 4 Fascia Adjustment Ribs
1 - FRONT UPPER FASCIA
2 - ADJUSTMENT RIBS
3 - FRONT LOWER FASCIA
Fig. 5 Front Bumper Lower Fascia
1 - LOWER FASCIA
2 - RETAINING CLIP
3 - BUMPER
BR/BEFRAME & BUMPERS 13 - 3
FRONT FASCIA (Continued)

REAR BUMPER
REMOVAL
(1) Support rear bumper on a suitable lifting
device.
(2) Remove nuts attaching rear bumper to inner
and outer brackets (Fig. 8).
(3) Disengage license plate lamp wire connector
from body wire harness, if equipped.
(4) Separate rear bumper from vehicle.
INSTALLATION
(1) Support rear bumper on a suitable lifting
device.
(2) Position rear bumper on vehicle.
(3) Engage license plate lamp wire connector to
body wire harness, if equipped.
(4) Install nuts attaching rear bumper to inner
and outer brackets. Tighten nuts to 94 N´m (70 ft.
lbs.) torque.
Fig. 7 Front Bumper & Fascia Ð Sport
1 - FASCIA
2 - U-NUT
3 - RETAINING CLIP
4 - OUTER BRACKET
5 - INNER BRACKET
6 - FRAME7 - FASCIA SUPPORT
8 - OUTER BRACKET
9 - PUSH-IN FASTENER
10 - AIR DEFLECTOR
11 - BUMPER
BR/BEFRAME & BUMPERS 13 - 5
FRONT BUMPERÐSPORT (Continued)

A fuel pressure test port is located on the fuel rail.
A quick-connect fitting with a safety latch clip is
used to attach the fuel line to the fuel rail.
The fuel rail is not repairable.
REMOVAL - 3.9L/5.2L/5.9L
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH ENGINE TURNED
OFF). BEFORE SERVICING FUEL RAIL ASSEMBLY,
FUEL SYSTEM PRESSURE MUST BE RELEASED.
To release fuel pressure, refer to Fuel System Pres-
sure Release Procedure found in this group.
CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate the rail
halves at the connecting hose (Fig. 27). Due to the
design of this connecting hose, it does use any
clamps. Never attempt to install a clamping device
of any kind to the hose. When removing the fuel rail
assembly for any reason, be careful not to bend or
kink the connecting hose.
(1) Remove negative battery cable at battery.
(2) Remove air cleaner.
(3) Perform fuel pressure release procedure.
(4) Remove throttle body from intake manifold.
Refer to Throttle Body removal in this group.
(5) If equipped with air conditioning, remove the
A-shaped A/C compressor-to-intake manifold support
bracket (three bolts) (Fig. 28).(6) Disconnect electrical connectors at all fuel
injectors. To remove connector refer to (Fig. 29). Push
red colored slider away from injector (1). While push-
ing slider, depress tab (2) and remove connector (3)
from injector. The factory fuel injection wiring har-
ness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. If harness is not
tagged, note wiring location before removal.
Fig. 27 Fuel Rail AssemblyÐTypical
1 - FUEL RAIL CONNECTING HOSE
2 - FUEL RAIL
3 - MOUNTING BOLTS (4)
Fig. 28 A/C Compressor Support BracketÐTypical
1 - AIR CONDITIONING COMPRESSOR SUPPORT BRACKET
2 - MOUNTING BOLTS
Fig. 29 Remove/Install Fuel Injector Connector
14 - 16 FUEL DELIVERY - GASOLINEBR/BE
FUEL RAIL (Continued)

INSTALLATION - 8.0L
(1) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(2) Install injector(s) and injector clip(s) to fuel
rail.
NOTE: The fuel injector electrical connectors on all
10 injectors should be facing to the right (passen-
ger) side of the vehicle (Fig. 34).
(3) Position the fuel rail/fuel injector assembly to
the injector openings on the intake manifold.
(4) Guide each injector into the intake manifold.
Be careful not to tear the injector o-ring.
(5) Push therightfuel rail down until fuel injec-
tors have bottomed on injector shoulder. Push the
leftfuel rail down until fuel injectors have bottomed
on injector shoulder.
(6) Install the six fuel rail mounting bolts into the
lower half of intake manifold. Tighten bolts to 15
N´m (136 in. lbs.) torque.
(7) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 33). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector. The injector wir-
ing harness is numerically tagged.
(8) Install upper half of intake manifold. Refer to
Engines for procedures.
(9) Connect main fuel line at fuel rail. Refer to
Quick-Connect Fittings for procedures.
(10) Install ignition coil pack and bracket assem-
bly at intake manifold and right engine valve cover
(four bolts).
(11) Install throttle body to intake manifold. Refer
to Throttle Body removal in this group.
(12) Install throttle body linkage to throttle body.
(13) Install air cleaner tube and housing.
(14) Install negative battery cable at battery.
(15) Start engine and check for leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.A rollover valve(s) is mounted into the top of the
fuel tank (or pump module). Refer to Emission Con-
trol System for rollover valve information.
An evaporation control system is connected to the
rollover valve(s) to reduce emissions of fuel vapors
into the atmosphere. When fuel evaporates from the
fuel tank, vapors pass through vent hoses or tubes to
a charcoal canister where they are temporarily held.
When the engine is running, the vapors are drawn
into the intake manifold. Certain models are also
equipped with a self-diagnosing system using a Leak
Detection Pump (LDP). Refer to Emission Control
System for additional information.
REMOVAL
WARNING: GASOLINE POWERED ENGINES: THE
FUEL SYSTEM IS UNDER A CONSTANT PRESSURE
EVEN WITH THE ENGINE OFF. BEFORE SERVICING
THE FUEL TANK, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO THE FUEL SYSTEM
PRESSURE RELEASE PROCEDURE BEFORE SER-
VICING THE FUEL TANK.
Two different procedures may be used to drain fuel
tank (lowering tank or using DRB scan tool). When
equipped with a diesel engine, the DRB scan tool
cannot be used (no electric fuel pump).
The quickest draining procedure involves lowering
the fuel tank.
Gasoline Powered Engines:As an alternative
procedure, the electric fuel pump may be activated
allowing tank to be drained at fuel rail connection.
Refer to DRB scan tool for fuel pump activation pro-
cedures. Before disconnecting fuel line at fuel rail,
release fuel pressure. Refer to the Fuel System Pres-
sure Release Procedure in this group for procedures.
Attach end of special test hose tool number 6541,
6539, 6631 or 6923 at fuel rail disconnection (tool
number will depend on model and/or engine applica-
tion). Position opposite end of this hose tool to an
approved gasoline draining station. Activate fuel
pump and drain tank until empty.
If electric fuel pump is not operating, tank must be
lowered for fuel draining. Refer to following proce-
dures.
(1) Remove fuel tank filler tube cap.
(2) Perform Fuel System Pressure Release proce-
dure as described in this group.
(3) Gasoline Engines: Disconnect negative battery
cable at battery. Diesel Engines: Disconnect both neg-
ative battery cables at both batteries.
(4) Raise vehicle on hoist.
(5) Certain models are equipped with a separate
grounding wire (strap) connecting the fuel fill tube
assembly to the body. Disconnect wire by removing
screw.
BR/BEFUEL DELIVERY - GASOLINE 14 - 19
FUEL RAIL (Continued)