2001 DODGE RAM Valve

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)

DIAGNOSIS AND TESTING - POWER STEERING SYSTEM
There is some noise in all power steering systems. One of the most common is a hissing sound evident at a
standstill parking. Or when the steering wheel is at the end of it's travel. Hiss is a high frequency noise similar
to that of a water tap being closed slowly. The noise is present in all valves that have a high velocity fluid passing
through an orifice. There is no relationship between this noise and steering performance.
STEERING NOISE
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONAL HISS OR
WHISTLE1. Steering intermediate shaft to dash panel
seal.1. Check and repair seal at dash
panel.
2. Noisy valve in power steering gear. 2. Repair steering gear.
RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension
components.2. Inspect and repair suspension.
3. Loose or damaged steering linkage. 3. Inspect and repair steering
linkage.
4. Internal gear noise. 4. Repair steering gear.
5. Pressure hose in contact with other
components.5. Reposition hose.
6. Loose or damaged intermediate shaft or
column.6. Inspect and repair or replace.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with other
components.2. Reposition hose.
3. Internal pump noise. 3. Replace pump.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on hose
fitting.2. Replace o-ring.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
5. Reservoir cap not installed correctly. 5. Install reservoir cap correctly.
SCRUBBING OR
KNOCKING1. Wrong tire size. 1. Verify tire size.
2. Wrong gear. 2. Verify gear.
19 - 2 STEERINGBR/BE
STEERING (Continued)

CONDITION POSSIBLE CAUSE CORRECTION
VEHICLE PULLS OR LEADS TO
ONE SIDE.1. Tire Pressure. 1. Adjust tire pressure.
2. Radial tire lead. 2. Rotate tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align front end.
DIAGNOSIS AND TESTING - POWER STEERING
FLOW AND PRESSURE
The following procedure is used to test the opera-
tion of the power steering system on the vehicle. This
test will provide the flow rate of the power steering
pump along with the maximum relief pressure. Per-
form test any time a power steering system problem
is present. This test will determine if the power
steering pump or power steering gear is not function-
ing properly. The following pressure and flow test is
performed using Power Steering Analyzer Tool kit
6815 (Fig. 2) and Adapter Kit 6893.
POWER STEERING ANALYZER INSTALLATION
WITHOUT HYDRAULIC BOOSTER
(1) Remove the high pressure hose from the power
steering pump.
(2) Connect Tube 6844 into the pump hose fitting.(3) Connect pressure gauge hose from the Power
Steering Analyzer to Tube 6844.
(4) Connect Adapter 6826 to Power Steering Ana-
lyzer test valve end.
(5) Connect the power steering hose from the
steering gear to Adapter 6826.
WITH HYDRAULIC BOOSTER
(1) Remove high pressure hose which goes to the
steering gear from the tube coming out of the booster.
(2) Connect Adapter 6826 to the Power Steering
Analyzer pressure gauge hose.
(3) Connect pressure gauge hose to the tube com-
ing out of the booster.
(4) Connect Tube 6844 to the steering gear hose
and Power Steering Analyzer test valve end.
FLOW AND PRESSURE TEST
(1) Check belt condition and tension.
(2) Open the test valve completely.
(3) Start engine and let idle long enough to circu-
late power steering fluid through flow/pressure test
gauge and to get air out of the fluid. Then shut off
engine.
(4) Check fluid level, add fluid as necessary. Start
engine again and let idle.
(5) Gauge should read below 1034 kPa (150 psi), if
above, inspect the hoses for restrictions and repair as
necessary. The initial pressure reading should be in
the range of 345-552 kPa (50-80 psi).
(6) Increase the engine speed to 1500 RPM and
read the flow meter. If the flow rate (GPM) is below
specification (Refer to pump specification chart for
GPM) the pump should be replaced.
CAUTION: The following test procedure involves
testing maximum pump pressure output and flow
control valve operation. Do not leave valve closed
for more than three seconds as the pump could be
damaged.
Fig. 2 Pressure Test Gauge
1 - GAUGE HOSE
2 - TUBE
3 - ADAPTER FITTINGS
4 - ANALYZER
19 - 4 STEERINGBR/BE
STEERING (Continued)

(7) Close valve fully three times and record high-
est pressure indicated each time.All three read-
ings must be above specifications and within
345 kPa (50 psi) of each other.
²Pressures above specifications but not within
345 kPa (50 psi) of each other, replace pump.
²Pressures within 345 kPa (50 psi) of each other
but below specifications, replace pump.
(8) Open the test valve and turn the steering
wheel to the extreme left and right positions three
times against the stops. Record the highest pressure
reading at each position. Compare the readings to
the pump specifications chart. If pressures readings
are not within 50 psi of each other, the gear is leak-
ing internally and must be repaired.
CAUTION: Do not force the pump to operate against
the stops for more than 2 to 3 seconds at a time
because, pump damage will result.PUMP SPECIFICATION
ENGINERELIEF PRESSURE
(P.S.I.)FLOW
(G.P.M.) at
1500 RPM
3.9L 1450 to 1550 2.7 to 3.1
5.2L 1450 to 1550 2.7 to 3.1
5.9L 1450 to 1550 2.7 to 3.1
8.0L 1450 to 1550 2.7 to 3.1
5.9L
Diesel1450 to 1550 3.1 to 3.5
All With
Hydraulic
Booster1450 to 1550 3.1 to 3.5
NOTE: After preforming test and removing Power
Steering Analyzer, check power steering fluid level.
BR/BESTEERING 19 - 5
STEERING (Continued)

GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION...........................14
OPERATION.............................14
DIAGNOSIS AND TESTING.................14
POWER STEERING GEAR LEAKAGE.......14
REMOVAL..............................16
INSTALLATION...........................16
ADJUSTMENTS..........................16
SPECIFICATIONS........................19
SPECIAL TOOLS.........................20
PITMAN BEARING
REMOVAL..............................20
INSTALLATION...........................21
PITMAN SHAFT
REMOVAL..............................22INSTALLATION...........................23
PITMAN SHAFT SEAL
REMOVAL..............................23
INSTALLATION...........................24
SPOOL VALVE
REMOVAL..............................24
INSTALLATION...........................26
STEERING GEAR HOUSING PLUG
REMOVAL..............................27
INSTALLATION...........................27
WORM SHAFT
REMOVAL..............................27
INSTALLATION...........................29
GEAR
DESCRIPTION
The power steering gear is a recirculating ball type
gear (Fig. 1). The gear ratio's used are 17.5:1 and
14:1.
OPERATION
The gear acts as a rolling thread between the
worm shaft and rack piston. The worm shaft is sup-
ported by a thrust bearing at the lower end and abearing assembly at the upper end. When the worm
shaft is turned from input from the steering column
the rack piston moves. The rack piston teeth mesh
with the pitman shaft. Turning the worm shaft, turns
the pitman shaft, which turns the steering linkage.
DIAGNOSIS AND TESTING - POWER STEERING
GEAR LEAKAGE
(1) Possible power steering gear leakage areas.
(Fig. 2).
19 - 14 GEARBR/BE

Fig. 1 Power Steering Gear
1 - THRUST BEARING
2 - O-RING SEAL
3 - INLET
4 - OUTLET
5 - SEAL
6 - TORSION BAR
7 - STUB SHAFT
8 - ADJUSTER PLUG
9 - THRUST BEARING10 - TEFLON SEALS
11 - SPOOL VALVE
12 - VALVE BODY
13 - WORMSHAFT
14 - PIN
15 - PITMAN SHAFT
16 - RACK PISTON
17 - TEFLON RING
BR/BEGEAR 19 - 15
GEAR (Continued)