Engine Intake Manifold DODGE RAM 2003 Service Repair Manual

(1) Disconnect both negative battery cables from
both batteries. Cover and isolate ends of cables.
(2) Thoroughly clean fuel lines at both the cylinder
head and injection pump ends.
(3) If removing fuel line at either #1 or #2 cylinder,
the intake manifold air heater elements must first be
removed from top of intake manifold. Refer to Intake
Air Heater Removal / Installation for procedures.
(4) If removing fuel line at #6 cylinder, a bracket
(Fig. 16) is located above fuel line connection at cyl-
inder head. Two bolts secure this bracket to rear of
cylinder head. The upper bolt hole is slotted. Loosen
(but do not remove) these 2 bracket bolts. Tilt
bracket down to gain access to #6 fuel line connec-
tion.
(5) Remove necessary insulated fuel line support
clamps (Fig. 17) and bracket bolts at intake manifold.
(6) Place shop towels around fuel lines at fuel rail
and injectors. If possible, do not allow fuel to drip
down side of engine.
CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE LINES ATTACHED TO A SEPA-
RATE FITTING (Fig. 18) , USE A BACK-UP WRENCH
ON FITTING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.(7) Carefully remove each fuel line from engine.
Note position of each while removing.Do not bend
lines while removing.
Fig. 15 TYPICAL TEST FOR LEAKS USING
CARDBOARD
1 - HIGH-PRESSURE LINE
2 - CARDBOARD
3 - TYPICAL HIGH-PRESSURE FITTINGFig. 16 BRACKET - #6 INJECTOR
1 - BRACKET
2 - REAR OF CYLINDER HEAD
3 - FUEL DRAIN MANIFOLD LINE (TO FUEL TANK)
4 - BANJO BOLT
5 - SLOTTED HOLE
6 - BRACKET BOLTS (2)
Fig. 17 FUEL INJECTOR RAIL
1 - FUEL RAIL MOUNTING BOLTS (3)
2 - INSULATED CLAMPS
3 - FUEL INJECTOR RAIL
14 - 70 FUEL DELIVERY - DIESELDR
FUEL LINES (Continued)

INSTALLATION
All high-pressure fuel lines are of the same length
and inside diameter. Correct high-pressure fuel line
usage and installation is critical to smooth engine
operation.
(1) Position fuel line support clamp to fuel line.
Install clamp nuts/bolts and tighten finger tight.
(2) Position proper fuel line to proper injector on
engine. Tighten fittings hand tight at both ends of
line.
(3) Tighten fuel lines at high pressure injector con-
nector to 30 N´m (22 lb. ft.).
(4) Tighten fuel lines at fuel rail to 30 N´m (22 lb.
ft.).
(5) Tighten clamp/support nuts and bolts.
(6) Install engine lifting bracket and bolt. Tighten
bolt to 77 N´m (56 lb.ft.).(7) If fuel line at either #1 or #2 cylinder has been
replaced, install intake manifold air heater elements
to top of intake manifold. Refer to Intake Air Heater
Removal / Installation for procedures.
(8) If fuel line at #6 cylinder has been replaced, tilt
metal bracket upward and tighten 2 bolts at rear of
cylinder head.
(9) Install remaining fuel line support clamps and
bracket bolts at intake manifold.
(10) Connect both negative battery cables to both
batteries.
(11) Prime fuel system. Refer to Fuel System
Priming.
(12) Check lines/fittings for leaks.
Fig. 18 HIGH PRESSURE FUEL LINES
1 - FUEL INJECTOR
2 - HIGH-PRESSURE LINE
3 - INJECTOR MOUNTING BOLTS
4 - FUEL INJECTOR RAIL5 - SEPARATE FITTING (TYPICAL)
6 - CONNECTOR TUBE RETAINER (FITTING)
7 - CONNECTOR TUBE
DRFUEL DELIVERY - DIESEL 14 - 71
FUEL LINES (Continued)

FUEL PRESSURE SENSOR
DESCRIPTION
The fuel pressure sensor is mounted vertically near
the top/center of the fuel rail.
OPERATION
The fuel pressure sensor monitors actual high-
pressure within the fuel rail. An output signal from
this sensor (relating to fuel pressure) is sent to the
Engine Control Module (ECM).
REMOVAL
The fuel pressure sensor is mounted vertically near
the top/center of the fuel rail (Fig. 19).
(1) Disconnect electrical connector at sensor.
(2) Remove sensor from fuel rail.
(3) Inspect sensor o-ring.
INSTALLATION
(1) Inspect fuel pressure sensor o-ring.
(2) Lubricate sensor o-ring with clean diesel fuel.
(3) Install sensor into fuel rail.
(4) To prevent leaks, sensormustbe tightened to
prescribed torque. Tighten sensor to 101 N´m (75 ft.
lbs.) torque.
(5) Connect electrical connector to sensor.
(6) Start engine and check for fuel leaks.
FUEL PRESSURE LIMITING
VA LV E
DESCRIPTION
The fuel pressure limiting valve is located on the
top of the fuel rail.
OPERATION
Fuel pressure at the fuel rail is monitered by the
fuel rail pressure sensor. If fuel pressure becomes
excessive, the pressure limiting valve opens and
vents excess pressure into the fuel drain circuit.
REMOVAL
The fuel pressure limiting valve is located on the
top of the fuel rail (Fig. 20).
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and pos-
sible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Thoroughly clean area at pressure limiting
valve.
(2) Remove banjo bolt (Fig. 20) at banjo fitting.
(3) Remove pressure limiting valve from intake
manifold.
Fig. 19 FUEL PRESSURE SENSOR/FUEL PRES.
LIMIT. VALVE
1 - ELEC. CONNECTOR
2 - BANJO BOLT
3 - FUEL PRESSURE LIMITING VALVE
4 - FUEL PRESSURE SENSOR
5 - TOP OF INTAKE HEATER MANIFOLD
14 - 72 FUEL DELIVERY - DIESELDR

OPERATION
The sensor sends an input to the Engine Control
Module (ECM) when it senses water in the fuel filter/
water separator. As the water level in the filter/sep-
arator increases, the resistance across the WIF
sensor decreases. This decrease in resistance is sent
as a signal to the ECM and compared to a high
water standard value. Once the value reaches 30 to
40 kilohms, the ECM will activate the water-in-fuel
warning lamp through CCD bus circuits. This all
takes place when the ignition key is initially put in
the ON position. The ECM continues to monitor the
input at the end of the intake manifold air heater
post-heat cycle.
REMOVAL
The Water-In-Fuel (WIF) sensor is located at the
side of fuel filter/water separator canister. Refer to
Fuel Filter/Water Separator Removal/Installation for
WIF sensor removal/installation procedures.
FUEL DRAIN CIRCUIT
OPERATION
The Fuel Drain Circuit incorporates several
sources of fuel return. Fuel travels from the fuel tank
to the fuel transfer pump and is forced through the
fuel filter. A portion of that fuel travels through the
fuel filter and into the fuel injection pump, while the
rest of the fuel flows through a passage in the fuel
filter housing. It then goes to a fuel drain line and
returns back to the fuel tank.
The fuel that flows to the fuel pump is pressurized
and sent into a passage in the fuel pump. At this
point the fuel is channeled into two passages. One
passage sends fuel to the FCA (Fuel Control Actua-
tor). The other passage sends fuel to the cascade
overflow valve. The overflow valve sends some fuel to
a lubrication passage. The rest of the fuel is sent to a
drain passage which connects to an external fuel
line. This fuel line is connected to the same fuel filter
housing passage that the fuel transfer pump is con-
nected to.
Fuel that travels through the FCA is pressurized
by the fuel injection pump and sent through an
external high pressure fuel line to the fuel rail. At
the fuel rail, fuel is sent to the fuel injectors. If fuel
pressure in the fuel rail becomes excessive, the pres-
sure limiting valve opens and sends fuel through an
external fuel line. This line is connected to the fuel
filter housing at the fuel pump drain.
At the fuel injector, fuel that is not injected is used
for lubrication of the fuel injectors. This fuel then
travels through an internal passage in the rear of the
cylinder head, an then into an external fuel line. This
line is connected to the vehicles fuel return line, and
returns excess fuel back to the fuel tank.
Fig. 29 FILTER HOUSING (LATE)
1 - FILTER HOUSING
2 - FUEL HEATER AND THERMOSTAT
3 - FUEL HEATER MOUNTING SCREWS
4 - FUEL HEATER ELEC. CONNECTOR
5 - WIF SENSOR
6 - WIF SENSOR ELEC. CONNECTOR
7 - DRAIN HOSE
8 - DRAIN VALVE MOUNTING SCREWS
9 - DRAIN VALVE
14 - 78 FUEL DELIVERY - DIESELDR
WATER IN FUEL SENSOR (Continued)

FUEL CONTROL ACTUATOR
DESCRIPTION
The Fuel Control Actuator (FCA) is located at the
rear of the high-pressure, fuel injection pump.
OPERATION
The Fuel Control Actuator (FCA) is an electroni-
cally controlled solenoid valve. The ECM controls the
amount of fuel that enters the high-pressure pumping
chambers by opening and closing the FCA based on a
demanded fuel pressure. When the FCA is opened,
the maximum amount of fuel is being supplied to the
fuel injection pump. Any fuel that does not enter the
injection pump is directed to the overflow valve. The
overflow valve regulates how much excess fuel is used
for lubrication of the pump and how much is returned
to the fuel tank through the drain manifold.
An audible click from the FCA is normal when
operating the key to either the ON or OFF positions.
REMOVAL
The Fuel Control Actuator (FCA) is located at the
rear of the high-pressure, fuel injection pump (Fig. 13).
(1) Clean FCA mounting area at rear of fuel injec-
tion pump with an evaporative-type cleaner.
(2) Disconnect electrical connector at FCA.
(3) Remove 2 FCA mounting bolts.
(4) Remove FCA from injection pump.
(5) After removal, inspect FCA for corrosion or
damage. Shake the FCA and listen for a rattle. If
FCA does not rattle, replace it.
INSTALLATION
(1) Install new o-rings to the Fuel Control Actua-
tor (FCA).
(2) Lubricate o-rings with clean, light grease.
(3) Using new mounting bolts, install FCA into
injection pump. Tighten the micro-encapsulated bolts
in two stages. First to 3 N´m (27 in. lbs.), and then to
7 N´m (62 in. lbs.) torque. Do not pause more than
two minutes between tightening stages as bolts may
lose their ability to retain torque.
(4) Ensure FCA is mounted flush to injection
pump.
(5) Connect electrical connector to FCA.
(6) Start engine and observe for leaks.
FUEL INJECTOR
DESCRIPTION
Six individual, solenoid actuated high-pressure fuel
injectors are used (Fig. 14). The injectors are vertically
mounted into a bored hole in the top of the cylinder
head. This bored hole is located between the intake/
exhaust valves. High-pressure connectors (Fig. 15),
mounted into the side of the cylinder head, connect
each fuel injector to each high-pressure fuel line.
Fig. 13 FUEL CONTROL ACTUATOR
1 - ACTUATOR MOUNTING BOLTS
2 - FCA (FUEL CONTROL ACTUATOR)
3 - ACTUATOR ELECTRICAL CONNECTOR
Fig. 14 FUEL INJECTOR - DIESEL
1 - SOLENOID ELECTRICAL CONNECTOR STUDS
2 - MOUNTING BOLTS
3 - MOUNTING PLATES
4- COPPER SEALING WASHER
5 - INJECTOR TIP
6 - INJECTOR O-RING
7 - INJECTOR ELECTRICAL SOLENOID
DRFUEL INJECTION - DIESEL 14 - 85

(3) The bottom of fuel injector is sealed to cylinder
head bore with a copper sealing washer (shim) of acertain thickness (Fig. 20). A new shim with correct
thickness must always be re-installed after removing
injector. Measure thickness of injector shim (Fig. 21).
Shim Thickness: 1.5 mm (.060º)
(4) Install new shim (washer) to bottom of injector.
Apply light coating of clean engine oil to washer. This
will keep washer in place during installation.
(5) Install new o-ring to fuel injector. Apply small
amount of clean engine oil to o-ring.
(6) Note fuel inlet port on high pressure connector.
This must be positioned towards intake manifold.
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.
(7) Install fuel injector hold down clamp and hold
down bolts. Alternately tighten clamp bolts to 10 N´m
(89 in. lbs.) torque.
(8) Connect injector solenoid wires and nuts to top
of injectors (Fig. 18). Tighten connector nuts to 1.5
Fig. 17 TOOL #9015 AND CONNECTOR TUBE
1 - CONNECTOR TUBE
2 - LOCATING PINS
3 - RUBBER O-RING
4 - TOOL #9015
Fig. 18 FUEL INJECTORS
1 - SOLENOID CONNECTIONS
2 - ROCKER HOUSING
3 - FUEL INJECTOR
4 - PASSTHROUGH CONNECTOR
Fig. 19 FUEL INJECTOR REMOVER - #9010
Fig. 20 FUEL INJECTOR SEALING WASHER (SHIM)
LOCATION
1 - FUEL INJECTOR
2 - COPPER SEALING WASHER (SHIM)
14 - 88 FUEL INJECTION - DIESELDR
FUEL INJECTOR (Continued)

N´m (14 in. lbs.).Be very careful not to over-
tighten these nuts as damage to fuel injector
will occur.
(9) Install exhaust rocker arm assembly.
(10) Set exhaust valve lash. Refer to Engine.
(11) Install high pressure connector and its
retainer nut. Tighten nut to 50 N´m (37 ft. lbs.)
torque.
(12) Install high pressure fuel line. Refer to Fuel
Line Installation.
(13) Install valve cover. Refer to Engine.
(14) Install breather assembly.
(15) Connect negative battery cables to both bat-
teries.
FUEL INJECTOR RAIL
DESCRIPTION
The fuel injector rail is bolted to the top of the
intake manifold.
OPERATION
The fuel rail is used as a distribution device to
supply high-pressure fuel to the high-pressure fuel
lines.
REMOVAL
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and pos-
sible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Disconnect both negative battery cables at both
batteries. Isolate ends of both cables.
(2) Disconnect electrical connector at fuel pressure
sensor.
(3) Remove banjo bolt at fuel limiting valve and
remove fuel limiting valve.
(4) Disconnect necessary wiring harness retention
clips from intake manifold.
(5) Lift 2 rubber covers to gain access to positive
(+), intake heater cable nuts. Remove 2 nuts and
remove 2 cables from studs.
(6) Carefully remove 4 high-pressure fuel lines
from top of injector rail engine. Note position of each
line while removing.Do not bend lines while
removing.
CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE LINES ATTACHED TO A SEPA-
RATE FITTING, USE A BACK-UP WRENCH ON FIT-
TING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.
(7) Carefully remove 2 high-pressure fuel lines at
each end of injector rail. Note position of each line
while removing.Do not bend lines while remov-
ing.
Fig. 21 MEASURING INJECTOR SEALING WASHER
(SHIM)
1 - SHIM
Fig. 22 CLEANING CYLINDER HEAD INJECTOR
BORE - TYPICAL BORE
1 - TYPICAL INJECTOR BORE
2 - WIRE BRUSH
DRFUEL INJECTION - DIESEL 14 - 89
FUEL INJECTOR (Continued)

(8) Remove 3 injector rail mounting bolts (Fig. 23).
(9) Remove rail from top of intake manifold.
INSTALLATION
(1) Clean any dirt/debris from top of intake mani-
fold and bottom of fuel rail.
(2) Position fuel rail to top of manifold and install
3 mounting bolts. Tighten 3 bolts to 24 N´m (18 ft.
lbs.) torque.
(3) Install all high-pressure lines to rail. Refer to
Fuel Lines for procedures.
(4) Reposition wiring harness to intake manifold
and install new tie wraps.
(5) Position fuel limiting valve and install banjo
bolt. Tighten bolt to 30 N´m (22 ft. lbs.) torque.
(6) Connect electrical connector to fuel pressure
sensor.
(7) Position 2 positive (+) cables to intake heater
studs. Install 2 nuts.
(8) Connect battery cables to both batteries.
(9) Start engine and check for leaks.
INLET AIR TEMPERATURE
SENSOR/PRESSURE SENSOR
DESCRIPTION
The combination, dual function Inlet Air Tempera-
ture/Pressure Sensor is located on the air cleaner (fil-
ter) cover.
OPERATION
The Inlet Air Temperature/Pressure Sensor is a
combination dual-function sensor. The sensor element
extends into the intake air stream at the top of the
air filter housing. Ambient air temperature as well as
barometric pressure is monitored by this sensor. The
Engine Control Module (ECM) monitors signals from
this sensor.
REMOVAL
The Inlet Air Temperature/Pressure Sensor is
located on the air cleaner cover (Fig. 24).
(1) Disconnect electrical connector at sensor (Fig.
25).
(2) Remove two Torx-type mounting screws.
(3) Remove sensor from air cleaner cover.
(4) Check condition of sensor o-ring (Fig. 26).
INSTALLATION
(1) Check condition of sensor o-ring.
(2) Position sensor into top of air cleaner cover
with a slight twisting action.
(3) Install 2 mounting screws.
(4) Install electrical connector.
Fig. 23 FUEL INJECTOR RAIL
1 - FUEL RAIL MOUNTING BOLTS (3)
2 - INSULATED CLAMPS
3 - FUEL INJECTOR RAIL
Fig. 24 IAT/PRESSURE SENSOR LOCATION - 5.9L
DIESEL
1 - CLIPS
2 - FILTER COVER
3 - FILTER MINDERŸ
4 - INLET AIR TEMPERATURE/ PRESSURE SENSOR
5 - FILTER HOUSING
14 - 90 FUEL INJECTION - DIESELDR
FUEL INJECTOR RAIL (Continued)

INTAKE AIR HEATER
DESCRIPTION
The intake manifold air heater element assembly
is located in the top of the intake manifold.
OPERATION
The air heater elements are used to heat incoming
air to the intake manifold. This is done to help
engine starting and improve driveability with cool or
cold outside temperatures.
Electrical supply for the 2 air heater elements is
controlled by the Engine Control Module (ECM)
through the 2 air heater relays. Refer to Intake Man-
ifold Air Heater Relays for more information.
Two heavy-duty cables connect the 2 air heater ele-
ments to the 2 air heater relays. Each of these cables
will supply approximately 95 amps at 12 volts to an
individual heating element within the heater block
assembly.
Refer to the Powertrain Diagnostic Procedures
manual for an electrical operation and complete
description of the intake heaters, including pre-heat
and post-heat cycles.
REMOVAL
If servicing either of the heater elements, the
entire block/element assembly must be replaced.
(1) Disconnect both negative battery cables at both
batteries. Cover and isolate ends of both cables.
(2) Remove both the intake manifold air intake
tube (above injection pump), and its rubber connector
hose (Fig. 27).
(3) Lift 2 rubber covers (Fig. 28) to gain access to 2
positive (+) cable nuts. Remove these 2 nuts (Fig. 29)
and remove 2 cables from studs.
(4) Disconnect ground strap (Fig. 28) at heater ele-
ment stud.
(5) Remove wiring harness clips.
(6) Remove engine oil dipstick tube bracket from
air inlet connection and fuel filter housing.
(7) Remove 4 housing mounting bolts (Fig. 28) and
remove heater element assembly.
INSTALLATION
If servicing either of the heater elements, the
entire block/element assembly must be replaced.
(1) Using 2 new gaskets, position element assem-
bly and air housing to intake manifold.
(2) Position ground cable to air housing.
(3) Install 4 housing bolts and tighten to 24 N´m
(18 ft. lbs.) torque.
(4) Connect 2 positive (+) heater cables at cable
mounting studs.Do not allow either of the cable
eyelets to contact any other metal source other
than the cable nuts/studs.
Fig. 25 INLET/PRESSURE SENSOR REMOVAL/
INSTALLATION
1 - INLET/PRESSURE SENSOR
2 - ELEC. CONNECTOR
3 - SENSOR MOUNTING SCREWS (2)
4 - TOP OF AIR FILTER COVER
Fig. 26 SENSOR O-RING
1 - IAT/PRESSURE SENSOR
2 - O-RING
DRFUEL INJECTION - DIESEL 14 - 91
INLET AIR TEMPERATURE SENSOR/PRESSURE SENSOR (Continued)

(5) Install engine oil dipstick tube and mounting
bolt.
(6) Connect rubber connector hose and intake tube
to air intake housing.
(7) Connect both negative battery cables at both
batteries.
INTAKE AIR HEATER RELAY
DESCRIPTION
The 2 intake manifold air heater relays are located
in the engine compartment. They are attached to a
common bracket. This bracket is attached to the
right battery tray (Fig. 30).
OPERATION
The Engine Control Module (ECM) operates the 2
heating elements through the 2 intake manifold air
heater relays.
Fig. 27 INTAKE TUBE AND CONNECTING HOSE
1 - MANIFOLD ABOVE HEATERS
2 - RUBBER CONNECTING HOSE
3 - METAL INTAKE TUBE
4 - CLAMPS (2)
Fig. 28 AIR HEATER MANIFOLD
1 - GROUND CABLE
2 - MOUNTING BOLTS (4)
3 - RUBBER COVERS
4 - OIL DIPSTICK TUBE
5 - DIPSTICK MOUNTING BOLT
6 - NUT (GROUND CABLE)
Fig. 29 AIR HEATER ELEMENTS
1 - MOUNTING BOLTS (4)
2 - AIR HEATER MANIFOLD
3 - INTAKE MANIFOLD
4 - HEATER ELEMENTS
5 - LOWER GASKET
6 - NUTS (2) POSITIVE CABLES
7 - UPER GASKET
14 - 92 FUEL INJECTION - DIESELDR
INTAKE AIR HEATER (Continued)