2001 DODGE RAM intake

DIAGNOSIS AND TESTING - BOOST PRESSURE
Two pressure gauges attached at two different
points are required for this test.(1) Obtain two 6828 fuel pressure test gauges
(equivalent gauges are OK).Gauge Consistency
Test:Connect the gauges together to a common pres-
sure source and verify pressure consistency of both
gauges. Do this consistency test at approximately 206
kPa (30 psi). If pressures are different, they can still
be used for test. Note and record differences in pres-
sures before testing. Make adjustments as necessary.
(2) Remove 3/4º pipe plug fitting at rear of intake
manifold (Fig. 2). Temporarily replace this fitting
with fitting reducer to adapt to pressure gauge.
Note: This pipe plug is located to front of MAP
sensor. Do not remove plug to rear of MAP sen-
sor. This is a COOLANT passage plug.
(3) Loosen hose clamp and disconnect rubber sig-
nal line (Fig. 3) from 1/8º brass fitting at front of tur-
bocharger.
(4) Remove 1/8º brass fitting (Fig. 3) from turbo-
charger. Temporarily replace this fitting with a 1/8º
ªTº fitting to adapt to pressure gauge.
(5) Reattach signal line to temporary ªTº.
(6) Attach first pressure gauge to intake manifold
fitting.
(7) Attach second pressure gauge to ªTº fitting at
turbocharger.
Engine must be at rated RPM and full load for the
test.
If gauge pressure differential is greater than 3 psi
(6 in. Hg), check intercooler and associated piping for
restrictions, plugging or damage.
Maximum pressure at intake manifold (rated rpm
and load) is 36±37 in/hg63 in/hg (17.7±18.2 psi6
1.5 psi).
Wastegate should open at no higher than 38.7
in/hg (19 psi) at wide open throttle, full load. If
wastegate is out of adjustment, a DTC may have
been set. Refer to Wastegate Adjustment in Engines
for adjustment procedures.
Fig. 2 Boost Pressure Test at Intake Manifold
1 - REAR OF INTAKE MANIFOLD
2 - 3/49PIPE PLUG
Fig. 3 Boost Pressure Test at Turbocharger
1 - TURBOCHARGER
2 - 1/89FITTING
3 - SIGNAL LINE
4 - WASTEGATE ACTUATOR
5 - CONTROL ROD
6 - OIL SUPPLY LINE
BR/BEFUEL INJECTION - DIESEL 14 - 89
FUEL INJECTION - DIESEL (Continued)

SPECIFICATIONS
TORQUE - DIESEL ENGINE
DESCRIPTION N m Ft. Lbs. In. Lbs.
Accelerator Pedal Position Sensor
Bracket Bolts12 105
Air Intake Housing Bolts 24 18
Banjo Fittings at top of Filter/Separator 24 18
Banjo Fittings at Fuel Return Lines 24 18
Banjo Fitting At Fuel Supply Line
(Injector Pump)24 18
Camshaft Position Sensor (CMP) Bolt 20 15
ECM Mounting Bolts 24 18
Engine Coolant Temperature (ECT)
Sensor14 10
Engine Lifting Bracket Bolts 77 57
Fuel Drain Manifold ªTº Fitting 12 106
Fuel Filter Canister Bracket Bolts 24 18
Fuel Filter Canister Mounting Nut 14 10
Fuel Filter Drain Valve Mounting
Screws3-5 30-40
Fuel Heater Screws 2-3 15-20
Fuel Injector Clamp Bolts 10 89
Fuel Pump Module Locknut 24-44 18-32
Fuel Tank Mounting Nuts 41 30
Fuel Transfer Pump Mounting Nuts 12 9
High-Pressure Fuel Line Fittings (at
Injectors)38 28
High-Pressure Fuel Line Fittings (at
Pump)24 18
High-Pressure Fuel Line Clamps-to-
Intake Manifold24 18
Hose Clamps at Intercooler Tube 8 72
Injection Pump-to-Injection Pump Gear
Nut170 125
Injection Pump Mounting Nuts 43 32
Intake Manifold Air Temperature (IAT)
Sensor14 10
Intake Manifold Air Heater Relay Bolts 4.5 40
Manifold Air Pressure (MAP) Sensor 14 10
PCM Mounting Bolts 4 35
Overflow Valve-to-Fuel Injection Pump 24 18
Water-In-Fuel (WIF) Sensor 2-3 15-20
14 - 90 FUEL INJECTION - DIESELBR/BE
FUEL INJECTION - DIESEL (Continued)

(1) Disconnect both negative battery cables at both
batteries.
(2) Remove cable cover (Fig. 6). Cable cover is
attached with 2 Phillips screws, 2 plastic retention
clips and 2 push tabs (Fig. 6). Remove 2 Phillips
screws and carefully pry out 2 retention clips. After
clip removal, push rearward on front tab, and
upward on lower tab for cover removal.
(3) Using finger pressure only, disconnect end of
speed control servo cable from throttle lever pin by
pulling forward on connector while holding lever
rearward (Fig. 7).DO NOT try to pull connector
off perpendicular to lever pin. Connector will
be broken.
(4) Using two small screwdrivers, pry throttle
cable connector socket from throttle lever ball (Fig.
7).Be very careful not to bend throttle lever
arm.
(5) Disconnect transmission control cable at lever
arm (if equipped). Refer to 21, Transmission.
(6) Squeeze pinch tabs on speed control cable (Fig.
7) and pull cable rearward to remove from cable
mounting bracket.
(7) Squeeze pinch tabs on throttle cable (Fig. 7)
and pull cable rearward to remove from cable mount-
ing bracket.
(8) If equipped with an automatic transmission,
refer to 21, Transmission for transmission control
cable removal procedures.
(9) Disconnect wiring harness clip (Fig. 8) at bot-
tom of bracket.
(10) Remove 6 mounting bolts (Fig. 8) and par-
tially remove APPS assembly from engine. After
assembly is partially removed, disconnect electrical
connector from bottom of sensor by pushing on con-
nector tab (Fig. 9).
(11) Remove APPS assembly from engine.
INSTALLATION
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. 6).
(1) Snap electrical connector into bottom of sensor.
(2) Position APPS assembly to engine and install 6
bolts. Tighten bolts to 12 N´m (105 in. lbs.) torque.
(3) Connect wiring harness clip (Fig. 8) at bottom
of bracket.
(4) If equipped with an automatic transmission,
refer to Group 21, Transmission for transmission con-
trol cable installation procedures.
(5) Install speed control cable into mounting
bracket. Be sure pinch tabs (Fig. 7) have secured
cable.(6) Install throttle cable into mounting bracket. Be
sure pinch tabs (Fig. 7) 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)ECM Calibration:Turn key to ON position.
Without starting engine, slowly press throttle pedal
to floor and then slowly release. This step must be
done (one time) to ensure accelerator pedal position
sensor calibration has been learned by ECM. If not
done, possible DTC's may be set.
(12) Use DRB scan tool to erase any DTC's from
ECM/PCM.
FUEL INJECTOR
DESCRIPTION
Six individual, high-pressure fuel injectors are
used. The injectors are vertically mounted (Fig. 10)
into a bored hole in the top of the cylinder head. This
bored hole is located between the intake/exhaust
valves.
Fig. 10 Fuel Injector Location
1 - CLAMP
2 - FUEL INJECTOR
3 - BORED HOLE
4 - SHIM
5 - BOLTS
BR/BEFUEL INJECTION - DIESEL 14 - 93
ACCELERATOR PEDAL POSITION SENSOR (Continued)

Always cover or cap any open fuel connections before
a fuel system repair is performed.
Each fuel injector connector tube contains an edge
filter (Fig. 13) that breaks up small contaminants
that enter the injector. The edge filter uses the injec-
tors pulsating high-pressure to break up most parti-
cles so they are small enough to pass through the
injector.The edge filters are not a substitute for
proper cleaning and covering of all fuel system
components during repair.
The bottom of each fuel injector is sealed to the
cylinder head with a1.5mmthick copper shim (gas-
ket) (Fig. 12). The correct thickness shim must
always be re-installed after removing an injector.
Fuel pressure in the injector circuit decreases after
injection. The injector needle valve is immediately
closed by the needle valve spring and fuel flow into
the combustion chamber is stopped. Exhaust gases
are prevented from entering the injector nozzle by
the needle valve.
DIAGNOSIS AND TESTINGÐFUEL INJECTOR
TEST
The fuel injectors are located in the top of the cylin-
der head between the intake/exhaust valves (Fig. 14).
A leaking fuel injector can cause fuel knock, poor
performance, black smoke, poor fuel economy and
rough engine idle. If fuel injector needle valve does
not operate properly, engine may misfire and produce
low power.
A leak in injection pump-to-injector high-pressure
fuel line can cause many of same symptoms as mal-
functioning injector. Inspect for leaks in high-pressure
lines before checking for malfunctioning fuel injector.
WARNING: THE INJECTION PUMP SUPPLIES HIGH-
PRESSURE FUEL OF UP TO APPROXIMATELY
120,000 kPa (17,400 psi) TO EACH INDIVIDUAL
INJECTOR THROUGH HIGH-PRESSURE LINES. FUEL
UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE SKIN AND CAUSE PERSONAL INJURY. WEAR
SAFETY GOGGLES AND ADEQUATE PROTECTIVE
CLOTHING. AVOID CONTACT WITH FUEL SPRAY
WHEN BLEEDING HIGH-PRESSURE FUEL LINES.
WARNING: DO NOT BLEED AIR FROM FUEL SYS-
TEM OF A HOT ENGINE. DO NOT ALLOW FUEL TO
SPRAY ONTO EXHAUST MANIFOLD WHEN BLEED-
ING AIR FROM FUEL SYSTEM.
(1) To determine which fuel injector is malfunc-
tioning, run engine and isolate each cylinder using
DRB scan tool.The DRB scan tool lists the injec-
tor firing order in both cylinder numerical
order (1±2±3±4±5±6), and actual firing order
(1±5±3±6±2±4).
(2) Note RPM drop for each cylinder. As an alter-
native, loosen high-pressure fuel line fitting at fuel
injector connector tube (Fig. 15). Listen for a change
in engine speed. After testing, tighten line fitting to
40 N´m (30 ft. lbs.) torque. If engine speed drops,
injector was operating normally. If engine speed
remains same, injector may be malfunctioning. Test
all injectors in same manner one at a time.
Fig. 14 Fuel Injector Connections
1 - CONNECTOR
2 - O-RING
3 - FERRULE
4 - FITTING
5 - FUEL LINE
6 - INJECTOR
Fig. 15 Inspecting Injector Operation
1 - HIGH-PRESSURE FUEL LINE
BR/BEFUEL INJECTION - DIESEL 14 - 95
FUEL INJECTOR (Continued)

(3) Once injector has been found to be malfunc-
tioning, remove it from engine and test it. Refer to
Fuel Injector Removal/Installation.
WARNING: FUEL INJECTOR TESTERS CAN
DEVELOP EXTREMELY HIGH PRESSURES. FUEL
UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE SKIN AND CAUSE PERSONAL INJURY.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-TECTIVE CLOTHING. AVOID CONTACT WITH FUEL
SPRAY WHEN OPERATING INJECTOR TESTOR.
(4) After injector has been removed, obtain bench-
mount fuel injector tester OTCt(SPXt) part number
4210 (Fig. 16) (or equivalent). Install Special Tool
number 8301 (Fuel Injector Adapter) to 4210 tester.
Install fuel injector into 8301 adapter. Be sure tip of
adapter tool 8301 is aligned to inlet hole at side of
injector (Fig. 17) before tightening tool. Tighten tool
8301 to injector. Position container below injector
before testing.
(5) Refer to operating instructions supplied with
pressure tester for procedures.
(a) Check opening pressure or ªpopº pressure.
Pressure should be approximately 31,026 kPa (310
bars) or (4500 psi6250 psi). If fuel injector needle
valve is opening (popping) too early or too late,
replace injector.
(b) Perform a leak-down test on injector. Apply
pressure with injector tester. The injector should
not leak (drip) fuel with pressure at approximately
20 bars (291 psi) lower than pop pressure.
(c) Operate tester lever quickly several times to
check injector spray pattern. Verify fuel is spraying
from each injector nozzle hole. Injector should also
spray evenly from each nozzle hole.
(d) Pay attention to size and shape of spray
plumes. They should all be equal. If possible, com-
pare spray pattern to that of a new fuel injector
with same part number. Checking each plume for
consistency is an excellent indicator of injector per-
formance. Even if only one nozzle hole is plugged,
significant performance problems could result.
(e) Look for burrs on injector inlet.
(f) Check nozzle holes for hole erosion or plug-
ging.
(g) Inspect end of nozzle for burrs or rough
machine marks.
(h) Look for cracks at nozzle end.
(i) Check nozzle color for signs of overheating.
Overheating will cause nozzle to turn a dark yel-
low/tan or blue (depending on overheating temper-
ature).
(j) Look at end of injector tube where it meets
injector. A small, shiny band should be seen at this
point. The band should have a consistent thick-
ness. If not, injector could be leaking into fuel
return.
(k) If any of these conditions occur, replace injec-
tor.
REMOVAL
The fuel injectors are located in the top of the cyl-
inder head between the intake/exhaust valves (Fig.
18).
Fig. 16 Fuel
1 - FUEL INJECTOR
2 - ADAPTOR TOOL 8301
3 - POP PRESSURE TESTER
Fig. 17 Installing Injector to Adaptor Tool 8301
1 - ADAPTOR TOOL 8301
2 - TIP
3 - FUEL INJECTOR
4 - INLET AT SIDE OF INJECTOR
14 - 96 FUEL INJECTION - DIESELBR/BE
FUEL INJECTOR (Continued)

CAUTION: Refer to Cleaning Fuel System Parts.
(1) Disconnect both negative battery cables from
both batteries. Cover and isolate ends of cables.
Each fuel injector is connected to each high-pres-
sure fuel line with a steel connector tube (Fig. 19).
This steel connector is positioned into cylinder head
and sealed with an o-ring. The connectors are con-
nected to high-pressure fuel lines with fittings (Fig.
19).
(2) If injector at #1 or #2 cylinder is being
removed, intake manifold air heater assembly must
be removed. Refer to Intake Manifold Air Heater
Removal/Installation.
(3) If injector at #5 cylinder is being removed,
remove engine lifting bracket (2 bolts).
(4) Thoroughly clean area around injector and
injector high-pressure lines before removal.
(5) Remove necessary high-pressure fuel lines.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL LINES - REMOVAL).Do not bend any high-
pressure fuel line to gain access to fuel injector.
Cover or cap any open fuel connections.
(6) Remove valve cover (Refer to 9 - ENGINE/CYL-
INDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL).
(7) Thread Special Tool 8324 (Fuel Injector Con-
nector Tube Remover) onto end of injector connector
tube (Fig. 20).
(8) Pull injector connector tube from cylinder head.
The injector connector tube must be removed
before attempting to remove fuel injector or
serious damage to fuel injector and tube will
result.
(9) Remove and discard old o-ring (Fig. 19) from
injector connector tube.
(10) Remove fuel injector hold down clamp bolt at
front end of clamp (Fig. 18).Do not loosen or
remove special (2 shouldered) bolt at rear end
of clamp.Remove injector clamp by sliding it from
shoulders on rear clamp bolt.
(11) Thread rod from Special Tool number 8318
(Fuel Injector Remover) into top of fuel injector (Fig.
21).
(12) Tighten nut on 8318 tool to pull (remove) fuel
injector from cylinder head.
(13) Remove and discard old o-ring from fuel injec-
tor.
(14) Remove and discard copper sealing washer
(shim) (Fig. 22) from bottom of injector.If copper
sealing washer has remained in cylinder head,
it must be removed.
Fig. 18 Fuel Injector Location
1 - CLAMP
2 - FUEL INJECTOR
3 - BORED HOLE
4 - SHIM
5 - BOLTS
Fig. 19 Fuel Injector Connections
1 - CONNECTOR
2 - O-RING
3 - FERRULE
4 - FITTING
5 - FUEL LINE
6 - INJECTOR
BR/BEFUEL INJECTION - DIESEL 14 - 97
FUEL INJECTOR (Continued)

INSTALLATION
The fuel injectors are located in the top of the cyl-
inder head between the intake/exhaust valves (Fig.
18).
(1) Inspect fuel injector.
(a) If necessary, perform pressure test of injector.
Refer to Fuel Injector Testing.
(b) Look for burrs on injector inlet.(c) Check nozzle holes for hole erosion or plug-
ging.
(d) Inspect end of nozzle for burrs or rough
machine marks.
(e) Look for cracks at nozzle end.
(f) Check nozzle color for signs of overheating.
Overheating will cause nozzle to turn a dark yel-
low/tan or blue (depending on overheating temper-
ature).
Fig. 20 Fuel Injector Connector Tube Removal
1 - FUEL INJECTOR CONNECTOR TUBE
2 - SPECIAL TOOL 8324
3 - CYLINDER HEAD
Fig. 21 Fuel Injector Removal
1 - FUEL INJECTOR REMOVAL TOOL 8318
2 - TIGHTEN NUT FOR INJECTOR TERMINAL
3 - THREAD INTO INJECTOR
Fig. 22 Fuel Injector Sealing Washer (Shim)
Location
1 - FUEL INJECTOR
2 - COPPER SEALING WASHER (SHIM)
Fig. 23 Measuring Injector Sealing Washer (Shim)
1 - SHIM
14 - 98 FUEL INJECTION - DIESELBR/BE
FUEL INJECTOR (Continued)

(g) If any of these conditions occur, replace injec-
tor.
(2) Thoroughly clean fuel injector cylinder head
bore with special Cummins wire brush tool or equiv-
alent (Fig. 24). Blow out bore hole with compressed
air.
(3) The bottom of fuel injector is sealed to cylinder
head bore with a copper sealing washer (shim) of a
certain thickness. A new shim with correct thickness
must always be re-installed after removing injector.
Measure thickness of injector shim (Fig. 23).Shim
Thickness: 1.5 mm (.060º)
(4) Install new shim (washer) to bottom of injector
(Fig. 22). Apply light coating of clean engine oil to
washer. This will keep washer in place during instal-
lation.
(5) Install new o-ring to fuel injector. Apply small
amount of clean engine oil to o-ring.
(6) Note fuel inlet hole on side of fuel injector. This
hole must be positioned towards injector connector
tube. Position injector into cylinder head bore being
extremely careful not to allow injector tip to touch
sides of bore. Press fuel injector into cylinder head
with finger pressure only.Do not use any tools to
press fuel injector into position. Damage to
machined surfaces may result.
(7) Position fuel injector hold down clamp into
shouldered bolt while aligning slot in top of injector
into groove in bottom of clamp. Tighten opposite
clamp bolt (Fig. 18) to 10 N´m (89 in. lbs.) torque.
(8) Install new o-ring to fuel injector connector
tube. Apply small amount of clean engine oil to
o-ring.
(9) Press injector connector tube into cylinder head
with finger pressure only.Do not use any tools topress tube into position. Damage to machined
surfaces may result.
(10) Connect high-pressure fuel lines. Refer to
High-Pressure Fuel Lines Removal/Installation.The
fuel line fitting torque is very critical.If fitting
is under torqued, the mating surfaces will not seal
and a high-pressure fuel leak will result. If fitting is
over torqued, the connector and injector will deform
and also cause a high-pressure fuel leak. This leak
will be inside cylinder head and will not be visible
resulting in a possible fuel injector miss and low
power.
(11) Install valve cover. (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION).
(12) (If necessary) install intake manifold air
heater assembly. Refer to Intake Manifold Air Heater
Removal/Installation.
(13) (If necessary) install engine lifting bracket.
Tighten 2 bolts to 77 N´m (57 ft. lbs.) torque.
(14) Connect negative battery cables to both bat-
teries.
(15) Bleed air from high-pressure lines (Refer to 14
- FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE).
FUEL INJECTION PUMP
RELAY
DESCRIPTION
The fuel injection pump relay is located in the
Power Distribution Center (PDC). Refer to label
under PDC cover for relay location.
OPERATION
The Engine Control Module (ECM) energizes the
electric fuel injection pump through the fuel injection
pump relay. Battery voltage is applied to the fuel
injection pump relay at all times. When the key is
turned ON, the relay is energized when a 12±volt sig-
nal is provided by the ECM. When energized,
12±volts is supplied to the Fuel Pump Control Mod-
ule. The Fuel Pump Control Module is located on the
top of the fuel injection pump and is non-servicable.
FUEL TEMPERATURE SENSOR
DESCRIPTION
Two different fuel temperature sensors are used.
One of the sensors is located inside of the Bosch
VP44 fuel injection pump and is a non-serviceable
part. The other fuel temperature sensor is located in
the top of the fuel filter housing and is serviceable
(serviceable if replacing the fuel heater).
Fig. 24 Cleaning Cylinder Head Injector BoreÐ
TYPICAL BORE
1 - INJECTOR BORE
2 - WIRE BRUSH
BR/BEFUEL INJECTION - DIESEL 14 - 99
FUEL INJECTOR (Continued)