key battery DODGE RAM 2003 Service Service Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 2003, Model line: RAM, Model: DODGE RAM 2003Pages: 2895, PDF Size: 83.15 MB
Page 722 of 2895
8W-10 POWER DISTRIBUTION
Component PageA/C Compressor Clutch....................8W-10-16, 43, 44
A/C Compressor Clutch Relay.................8W-10-16, 43, 44
A/C-Heater Control......................8W-10-46, 47, 58
Adjustable Pedal Relay......................8W-10-14, 34
Adjustable Pedal Switch.................8W-10-14, 34, 46, 58
Airbag Control Module......................8W-10-46, 48
Airbag Control Module-Left Side Impact...............8W-10-46
Airbag Control Module-Right Side Impact..............8W-10-46
Ambient Temperature Sensor...................8W-10-52, 54
Amplifier Audio...........................8W-10-33
Auto Shut Down Relay......................8W-10-11, 18
Automatic Day/Night Mirror...................8W-10-45, 52
Auxiliary Battery...........................8W-10-11
Backup Lamp Switch.......................8W-10-48, 53
Battery..............................8W-10-11, 18
Blower Motor.............................8W-10-56
Brake Lamp Switch....................8W-10-13, 32, 43, 44
Capacitor.............................8W-10-21, 23
Center High Mounted Stop Lamp/Cargo Lamp............8W-10-42
Cigar Lighter Outlet.........................8W-10-50
Circuit Breaker............................8W-10-56
Clearance Lamp No. 1........................8W-10-37
Clearance Lamp No. 2........................8W-10-37
Clearance Lamp No. 3........................8W-10-37
Clearance Lamp No. 4........................8W-10-37
Clearance Lamp No. 5........................8W-10-37
Clutch Interlock Brake Switch....................8W-10-39
Coil On Plug No. 1........................8W-10-19, 22
Coil On Plug No. 2........................8W-10-20, 21
Coil On Plug No. 3........................8W-10-19, 22
Coil On Plug No. 4........................8W-10-20, 21
Coil On Plug No. 5........................8W-10-19, 22
Coil On Plug No. 6........................8W-10-20, 21
Coil On Plug No. 7........................8W-10-19, 22
Coil On Plug No. 8........................8W-10-20, 21
Compass/Mini-Trip Computer...................8W-10-42, 45
Condenser Fan..........................8W-10-17, 49
Condenser Fan Relay.......................8W-10-17, 49
Controller Antilock Brake...................8W-10-13, 30, 48
Data Link Connector.......................8W-10-32, 54
Dome Lamp.............................8W-10-42
Door Lock Switch-Passenger.....................8W-10-45
Driver Door Module.......................8W-10-42, 56
Electric Brake Provision.......................8W-10-18
Engine Control Module........................8W-10-43
EVAP/Purge Solenoid.........................8W-10-45
Fender Lamp-Front Left.......................8W-10-37
Fender Lamp-Front Right......................8W-10-37
Fender Lamp-Rear Left.......................8W-10-37
Fender Lamp-Rear Right.......................8W-10-37
Fog Lamp Relay.........................8W-10-15, 38
Fog Lamp-Left............................8W-10-38
Fog Lamp-Right...........................8W-10-38
Front Control Module....8W-10-12, 31, 32, 34, 35, 36, 48, 45, 51, 52, 54 , 55
Fuel Heater.............................8W-10-57
Fuel Heater Relay........................8W-10-17, 57
Fuel Injector No. 1........................8W-10-22, 24
Fuel Injector No. 2....................8W-10-20, 21, 23, 24
Fuel Injector No. 3........................8W-10-22, 24
Fuel Injector No. 4....................8W-10-20, 21, 23, 24
Fuel Injector No. 5........................8W-10-22, 24
Fuel Injector No. 6....................8W-10-20, 21, 23, 24
Fuel Injector No. 7........................8W-10-22, 24
Fuel Injector No. 8....................8W-10-20, 21, 23, 24
Fuel Injector No. 9..........................8W-10-24
Fuel Injector No. 10.........................8W-10-23
Fuel Pump Module........................8W-10-16, 42
Fuel Pump Relay.....................8W-10-16, 42, 43, 44
Fuse 1..............................8W-10-11, 18
Fuse 2............................8W-10-11, 12, 18
Fuse 3..............................8W-10-12, 26
Fuse 4..............................8W-10-12, 26
Fuse 5.......................8W-10-11, 12, 13, 27, 28, 29
Fuse 6............................8W-10-12, 13, 30
Fuse 7..............................8W-10-13, 30
Fuse 8..............................8W-10-14, 31
Fuse 9..............................8W-10-12, 26
Fuse 10..............................8W-10-12, 26
Fuse 11............................8W-10-12, 13, 32
Fuse 12............................8W-10-17, 49, 57
Fuse 13..............................8W-10-12, 32
Fuse 14..............................8W-10-14, 39
Fuse 15............................8W-10-15, 16, 36
Fuse 16............................8W-10-16, 43, 44
Fuse 17............................8W-10-16, 17, 42
Fuse 18..............................8W-10-13, 32
Fuse 19..............................8W-10-13, 33
Fuse 20..............................8W-10-12, 26
Fuse 21..............................8W-10-13, 33
Fuse 22..............................8W-10-13, 33
Fuse 24..............................8W-10-13, 32
Fuse 25..............................8W-10-13, 33
Fuse 27............................8W-10-16, 17, 47
Fuse 28............................8W-10-43, 44, 45
Fuse 32..............................8W-10-16, 36
Fuse 33..............................8W-10-16, 36Component PageFuse 34..............................8W-10-16, 36
Fuse 35...............................8W-10-48
Fuse 36..............................8W-10-47, 58
Fuse 37...............................8W-10-48
Fuse 38..............................8W-10-47, 48
Fuse 40............................8W-10-14, 15, 34
Fuse 41..............................8W-10-15, 38
Fuse 42..............................8W-10-13, 34
Fuse 43..............................8W-10-13, 34
Fuse 45............................8W-10-15, 16, 38
Fuse 46............................8W-10-14, 15, 35
Fuse 47..............................8W-10-15, 35
Fuse 48..............................8W-10-14, 34
Fuse 49..............................8W-10-11, 18
Fuse 50...............................8W-10-45
Fuse 51............................8W-10-13, 14, 32
Fuse 52..............................8W-10-47, 48
Fuse 53...............................8W-10-45
Fusible Link.............................8W-10-11
G103...............................8W-10-51, 52
G106...........................8W-10-31, 51, 55, 57
G107...............................8W-10-27, 29
G201.................................8W-10-26
Generator.............................8W-10-11, 28
Glove Box Lamp And Switch.....................8W-10-42
Headlamp Switch..........................8W-10-38
Headlamp-Left............................8W-10-55
Headlamp-Right...........................8W-10-55
Heated Mirror Relay.......................8W-10-17, 47
Horn Relay............................8W-10-15, 38
Horn-High Note...........................8W-10-38
Horn-Low Note............................8W-10-38
Ignition Coil.............................8W-10-24
Ignition Coil-Left...........................8W-10-23
Ignition Coil-Right..........................8W-10-23
Ignition Switch................8W-10-12, 26, 39, 45, 48, 50, 56
Instrument Cluster................8W-10-13, 26, 32, 33, 45, 50
Integrated Power Module . 8W-10-2, 3, 5, 11, 12, 13,, 14, 15, 16, 17, 18, 26, 27,
28, 29, 30, 31, 32, 33, 34, 35, 36, 38, 39, 42, 43, 44, 45, 46, 47, 48, 49, 50, 52,
54, 55, 57, 58
Leak Detection Pump........................8W-10-28
License Lamp-Left..........................8W-10-36
License Lamp-Right.........................8W-10-37
Overhead Map/Reading Lamp....................8W-10-42
Oxygen Sensor 1/1 Upstream.....................8W-10-25
Oxygen Sensor 1/2 Downstream...................8W-10-25
Oxygen Sensor 2/1 Upstream.....................8W-10-25
Oxygen Sensor 2/2 Downstream...................8W-10-25
Oxygen Sensor Downstream Relay................8W-10-11, 18
Park Lamp Relay.........................8W-10-16, 36
Park/Turn Signal Lamp-Left Front................8W-10-36, 51
Park/Turn Signal Lamp-Right Front...............8W-10-36, 51
Passenger Airbag On/Off Switch...................8W-10-46
Passenger Lumbar Switch......................8W-10-30
Power Mirror-Left..........................8W-10-47
Power Mirror-Right.........................8W-10-47
Power Outlet...........................8W-10-13, 33
Power Outlet-Console........................8W-10-34
Power Seat Switch-Driver......................8W-10-30
Power Seat Switch-Passenger....................8W-10-30
Power Window Circuit Breaker....................8W-10-56
Powertrain Control Module . 8W-10-17, 18, 19, 21, 23, 24, 28, 29, 33, 39, 40, 41,
42, 43, 44, 49, 57
PTCNo.1.........................8W-10-42, 43, 44, 45
PTCNo.2 ..............................8W-10-50
PTCNo.5 ..............................8W-10-35
Radio...............................8W-10-32, 50
Seat Belt Tensioner Reducer.....................8W-10-50
Seat Heater Interface Module....................8W-10-34
Sentry Key Immobilizer Module...............8W-10-33, 43, 44
Spare Relay.............................8W-10-58
Starter Motor...........................8W-10-14, 39
Starter Motor Relay.......................8W-10-14, 39
Tail/Stop/Turn Signal Lamp-Left.............8W-10-36, 51, 52, 54
Tail/Stop/Turn Signal Lamp-Right.............8W-10-37, 51, 52, 54
Tailgate Lamp Assembly.....................8W-10-36, 41
Trailer Tow Connector...................8W-10-15, 16, 35, 36
Trailer Tow Connector-Add On..............8W-10-18, 35, 36, 52
Trailer Tow Left Turn Relay...................8W-10-15, 35
Trailer Tow Right Turn Relay...................8W-10-15, 35
Transfer Case Control Module................8W-10-13, 34, 39
Transmission Control Module...............8W-10-12, 27, 41, 56
Transmission Control Relay................8W-10-12, 27, 28, 29
Transmission Range Sensor..................8W-10-40, 48, 53
Transmission Solenoid Assembly.................8W-10-12, 28
Transmission Solenoid/TRS Assembly.........8W-10-27, 29, 40, 48, 53
Underhood Lamp...........................8W-10-32
Vacuum Pump............................8W-10-43
Vistronic Fan Drive.........................8W-10-58
Washer Fluid Level Switch....................8W-10-52, 54
Washer Pump Motor-Front......................8W-10-52
Wiper High/Low Relay......................8W-10-14, 31
Wiper Motor-Front........................8W-10-31, 52
Wiper On/Off Relay........................8W-10-14, 31
DR8W-10 POWER DISTRIBUTION 8W - 10 - 1
Page 780 of 2895
8W-15 GROUND DISTRIBUTION
Component Page
A/C Compressor Clutch..................8W-15-9, 11
A/C-Heater Control....................8W-15-15, 17
Adjustable Pedal Switch...................8W-15-17
Airbag Control Module....................8W-15-18
Airbag Control Module-Left Side Impact.........8W-15-18
Airbag Control Module-Right Side Impact........8W-15-18
Amplifier Audio........................8W-15-14
Automatic Day/Night Mirror................8W-15-15
Auxiliary Battery........................8W-15-7
Battery..............................8W-15-7
Brake Lamp Switch......................8W-15-13
Brake Transmission Shift Interlock Solenoid.......8W-15-14
Center High Mounted Stop Lamp/Cargo Lamp.....8W-15-15
Cigar Lighter Outlet.....................8W-15-17
Clearance Lamp No. 1....................8W-15-16
Clearance Lamp No. 2....................8W-15-16
Clearance Lamp No. 3....................8W-15-16
Clearance Lamp No. 4....................8W-15-16
Clearance Lamp No. 5....................8W-15-16
Clockspring...........................8W-15-12
Clutch Interlock Brake Switch..............8W-15-2, 5
Compass/Mini-Trip Computer................8W-15-15
Condenser Fan........................8W-15-4, 6
Controller Antilock Brake...................8W-15-4
Cylinder Lock Switch-Driver................8W-15-19
Cylinder Lock Switch-Passenger..............8W-15-19
Data Link Connector.....................8W-15-13
Data Link Connector-Engine................8W-15-11
Door Ajar Switch-Driver...................8W-15-19
Door Ajar Switch-Left Rear.................8W-15-20
Door Ajar Switch-Passenger.................8W-15-19
Door Ajar Switch-Right Rear................8W-15-20
Door Lock Motor/Ajar Switch-Driver............8W-15-19
Door Lock Motor/Ajar Switch-Left Rear..........8W-15-20
Door Lock Motor/Ajar Switch-Passenger.........8W-15-19
Door Lock Motor/Ajar Switch-Right Rear.........8W-15-20
Door Lock Switch-Passenger.................8W-15-19
Driver Door Module......................8W-15-21
Electric Brake Provision..................8W-15-4, 6
Engine Control Module....................8W-15-11
Fender Lamp-Front Left....................8W-15-3
Fender Lamp-Front Right...................8W-15-3
Fender Lamp-Rear Left....................8W-15-3
Fender Lamp-Rear Right...................8W-15-3
Fog Lamp-Left........................8W-15-2, 5
Fog Lamp-Right.......................8W-15-2, 5
Fuel Heater...........................8W-15-11
Fuel Pump Module....................8W-15-3, 4, 6
G100................................8W-15-7
G101................................8W-15-7
G102................................8W-15-7
G103................................8W-15-2
G104..............................8W-15-5, 6
G105................................8W-15-7
G106................................8W-15-4
G107............................8W-15-8, 9, 10
G108................................8W-15-7
G109................................8W-15-7
G114 ...............................8W-15-11
G117 ...............................8W-15-11
Component Page
G120...............................8W-15-11
G201.............................8W-15-12, 13
G202.............................8W-15-14, 15
G203...............................8W-15-17
G204...............................8W-15-18
G301...............................8W-15-20
G302...............................8W-15-22
Generator..........................8W-15-10, 11
Headlamp Switch.......................8W-15-12
Headlamp-Left........................8W-15-2, 5
Headlamp-Right.........................8W-15-7
Heated Seat Cushion-Driver.................8W-15-22
Heated Seat Cushion-Passenger..............8W-15-22
Heated Seat Switch-Driver.................8W-15-13
Heated Seat Switch-Passenger...............8W-15-13
Horn-High Note.......................8W-15-4, 6
Horn-Low Note........................8W-15-4, 6
Ignition Switch.........................8W-15-12
Instrument Cluster....................8W-15-12, 14
Intake Air Heater Relay No. 1................8W-15-7
Intake Air Heater Relay No. 2................8W-15-7
Integrated Power Module..............8W-15-2, 4, 5, 8
Leak Detection Pump.....................8W-15-10
License Lamp-Left.......................8W-15-3
License Lamp-Right......................8W-15-3
Lift Pump Motor........................8W-15-11
Overdrive Switch.......................8W-15-13
Oxygen Sensor 1/1 Upstream................8W-15-10
Oxygen Sensor 1/2 Downstream.............8W-15-9, 10
Oxygen Sensor 2/1 Upstream................8W-15-10
Oxygen Sensor 2/2 Downstream.............8W-15-9, 10
Park/Turn Signal Lamp-Left Front............8W-15-2, 6
Park/Turn Signal Lamp-Right Front............8W-15-7
Power Mirror-Left.......................8W-15-21
Power Mirror-Right......................8W-15-22
Power Outlet..........................8W-15-17
Power Outlet-Console.....................8W-15-21
Power Seat Switch-Driver..................8W-15-21
Power Seat Switch-Passenger................8W-15-21
Power Steering Pressure Switch...............8W-15-9
Powertrain Control Module.............8W-15-8, 10, 11
Radio...............................8W-15-15
Red Brake Warning Indicator Switch..........8W-15-2, 6
Seat Belt Switch-Driver...................8W-15-20
Seat Heater Interface Module................8W-15-22
Sentry Key Immobilizer Module..............8W-15-12
Speed Control Servo.....................8W-15-2, 5
Tail/Stop/Turn Signal Lamp-Left...............8W-15-3
Tail/Stop/Turn Signal Lamp-Right..............8W-15-3
Tailgate Lamp Assembly....................8W-15-3
Trailer Tow Connector..................8W-15-3, 4, 6
Trailer Tow Connector-Add On.............8W-15-3, 4, 6
Transfer Case Control Module...............8W-15-17
Transfer Case Selector Switch................8W-15-13
Transmission Control Module.................8W-15-8
Underhood Lamp.......................8W-15-2, 6
Vacuum Pump..........................8W-15-7
Washer Pump Motor-Front.................8W-15-4, 7
Wiper Motor-Front....................8W-15-2, 4, 5
DR8W-15 GROUND DISTRIBUTION 8W - 15 - 1
Page 1470 of 2895
(14) Remove crankshaft damper(Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
NOTE: Do not remove the hoses from the power
steering pump.
(15) Remove power steering pump and set aside.
(16) Remove the dipstick support bolt.
(17) Drain the engine oil.
(18) Remove the oil pan and pick up tube(Refer to
9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
NOTE: It is not necessary to remove water pump for
timing cover removal.
(19) Remove timing cover bolts and remove cover.
INSTALLATION
(1) Clean timing chain cover and block surface.
NOTE: Always install a new gasket on timing cover.
(2) Install cover and new gasket. Tighten fasteners
to 28 N´m (250 in. lbs.).
NOTE: The large lifting stud is torqued to 55 N´m
(40 ft. lbs.).
(3) Install the oil pan and pick up tube(Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(4) Install the A/C compressor.
(5) Install the generator.
(6) Install power steering pump.
(7) Install the dipstick support bolt.
(8) Install the thermostat housing.
(9) Install crankshaft damper(Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(10) Install accessory drive belt tensioner assembly
and both idler pulleys.
(11) Install radiator lower hose.
(12) Install both heater hoses.
(13) Install radiator fan shroud.
(14) Install the fan and fan drive assembly
(15) Install the accessory drive belt.
(16) Install the coolant bottle and washer bottle.
(17) Install the upper radiator hose.
(18) Install the air cleaner assembly.
(19) Fill cooling system.
(20) Refill engine oil.
(21) Connect the battery negative cable.
TIMING/CHAIN AND
SPROCKETS
REMOVAL
(1) Disconnect battery negative cable.
(2) Drain cooling system.
(3) Remove Timing Chain Cover.
CAUTION: The camshaft pin and the slot in the cam
sprocket must be clocked at 12:00. The crankshaft
keyway must be clocked at 2:00. The crankshaft
sprocket must be installed so that the dots and or
paint marking is at 6:00.
(4) Re-install the vibration damper bolt finger
tight. Using a suitable socket and breaker bar, rotate
the crankshaft to align timing chain sprockets and
keyways as shown (Fig. 31).
(5) Retract tensioner shoe until hole in shoe lines
up with hole in bracket. Slide a suitable pin into the
holes.
(6) Remove camshaft sprocket attaching bolt and
remove timing chain with crankshaft and camshaft
sprockets.
(7) If tensioner assembly is to be replaced, remove
the tensioner to block bolts and remove tensioner
assembly.
Fig. 31 5.7L TIMING MARK ALIGNMENT
1 - Chain Tensioner
2 - Camshaft Sprocket
3 - Crankshaft Sprocket
DRENGINE - 5.7L 9 - 221
TIMING/CHAIN COVER (Continued)
Page 1471 of 2895
INSTALLATION
(1) If tensioner assembly is being replaced, install
tensioner and mounting bolts. Torque bolts to 28 N´m
(250 in. lbs.).
(2) Retract tensioner if required.
CAUTION: The camshaft pin and the slot in the cam
sprocket must be clocked at 12:00. The crankshaft
keyway must be clocked at 2:00. The crankshaft
sprocket must be installed so that the dots and or
paint marking is at 6:00.
(3) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores (Fig. 32).
CAUTION: The timing chain must be installed with
the single plated link aligned with the dot and or
paint marking on the camshaft sprocket. The crank-
shaft sprocket is aligned with the dot and or paint
marking on the sprocket between two plated timing
chain links.
(4) Place timing chain around both sprockets (Fig.
32).
(5) Lift sprockets and chain (keep sprockets tight
against the chain in position as shown).(6) Slide both sprockets evenly over their respec-
tive shafts and check alignment of timing marks.
(7) Install the camshaft bolt. Tighten the bolt to
122 N´m (90 ft. lbs.) torque.
(8)Remove tensioner pin.Again, verify align-
ment of timing marks.
(9) Install the oil pump(Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(10) Install the oil pan and pick up(Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(11) Install the timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(12) Fill cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(13) Connect battery negative cable.
(14) Start engine and check for oil and coolant
leaks.
TIMING CHAIN/TENSIONER
DESCRIPTION
The timing chain tensioner is a stamped steel con-
stant tension mechanical design. It is mounted to the
front of the engine, behind the timing chain drive.
OPERATION
The timing chain tension is maintained by routing
the timing chain through the tensioner assembly. A
nylon covered spring steel arm presses on the timing
chain maintaining the correct chain tension.
Fig. 32 5.7L TIMING MARK ALIGNMENT
1 - Chain Tensioner
2 - Camshaft Sprocket
3 - Crankshaft Sprocket
9 - 222 ENGINE - 5.7LDR
TIMING/CHAIN AND SPROCKETS (Continued)
Page 1528 of 2895
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove Timing Chain Cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(3) Re-install the vibration damper bolt finger
tight. Using a suitable socket and breaker bar, rotate
the crankshaft to align timing marks as shown in
(Fig. 76).
(4) Remove camshaft sprocket attaching bolt and
remove timing chain with crankshaft and camshaft
sprockets.
INSPECTIONÐMEASURING TIMING CHAIN
STRETCH
(1) Place a scale next to the timing chain so that
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam-
shaft sprocket attaching bolt. Apply torque in the
direction of crankshaft rotation to take up slack; 41
N´m (30 ft. lbs.) torque with cylinder head installed
or 20 N´m (15 ft. lbs.) torque with cylinder head
removed. With a torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads
installed, apply 14 N´m (30 ft. lbs.) torque in the
reverse direction. With the cylinder heads removed,
apply 20 N´m (15 ft. lbs.) torque in the reverse direc-
tion. Note the amount of chain movement (Fig. 77).
(4) Install a new timing chain, if its movement
exceeds 3.175 mm (1/8 inch).
INSTALLATION
(1) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exactimaginary center line through both camshaft and
crankshaft bores.
(2) Place timing chain around both sprockets.
(3) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(4) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(5) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 78).
(6) Install the camshaft bolt. Tighten the bolt to 68
N´m (50 ft. lbs.) torque.
(7) Check camshaft end play. The end play should
be 0.051-0.152 mm (0.002-0.006 inch) with a new
thrust plate and up to 0.254 mm (0.010 inch) with a
used thrust plate. If not within these limits install a
new thrust plate.
(8) Install the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
Fig. 76 Alignment of Timing Marks
1 - TIMING MARKS
Fig. 77 Measuring Timing Chain Stretch
1 - TORQUE WRENCH
2 - 3.175 MM
(0.125 IN.)
Fig. 78 Alignment of Timing Marks
1 - TIMING MARKS
DRENGINE - 5.9L 9 - 279
Page 1597 of 2895
(8) Install the oil drain tube and a new gasket to
the turbocharger. Tighten the drain tube bolts to 24
N´m (18 ft. lbs.) torque.
(9)Pre-lube the turbocharger.Pour 50 to 60 cc
(2 to 3 oz.) clean engine oil in the oil supply line fit-
ting on the turbo. Rotate the turbocharger impeller
by hand to distrubute the oil thoroughly.
(10) Install and tighten the oil supply line fitting
nut to 24 N´m (18 ft. lbs.) torque.
(11) Position the charge air cooler inlet pipe to the
turbocharger. With the clamp in position, tighten the
clamp nut to 8 N´m (72 in. lbs.) torque.
(12) Position the air inlet hose to the turbocharger.
Tighten the clamp to 8 N´m (72 in. lbs.) torque.
(13) Raise vehicle on hoist.
(14) Connect the exhaust pipe to the turbocharger
and tighten the bolts to 34 N´m (25 ft. lbs.) torque.
(15) Lower the vehicle.
(16) Connect the battery negative cables.
(17) Start the engine to check for leaks.
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION
(1) Remove the cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(2) Remove fuel injector from cylinder number
1(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL).
(3) Using Special Tool 7471B rotate the engine
until the TDC mark on the damper is at 12 o'clock.
(4) Using a 8 in.x 1/4 in. dowel rod inserted into
cylinder number 1, rock the crankshaft back and
forth to verify piston number 1 is at TDC.
(5) With cylinder number still at TDC, inspect the
keyway on the crankshaft gear for proper alignment
(12 o'clock position).
(6) If the keyway is not at 12 o'clock position
replace the crankshaft gear assembly.
(7) If the keyway is at 12 o'clock position, remove
front gear cover and verify timing mark alignment
between the camshaft gear and crankshaft gear, if
not aligned inspect keyway on camshaft gear.
(8) Inspect keyway on camshaft gear for proper
alignment with the key in the camshaft, if alignment
is off replace the camshaft/gear assembly.
(9) If timing marks alignment is off and no dam-
age is found at either the crankshaft or camshaft
gear keyways, realign timing marks as necessary.
GEAR HOUSING
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Partially drain engine coolant into container
suitable for re-use (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(4) Lower vehicle.
(5) Remove radiator upper hose.
(6) Disconnect coolant recovery bottle hose from
radiator filler neck and lift bottle off of fan shroud.
(7) Disconnect windshield washer pump supply
hose and electrical connections and lift washer bottle
off of fan shroud.
(8) Remove lower fan shroud fasteners. Disconnect
fan drive wire harness.
(9) Remove the upper fan shroud-to-radiator
mounting bolts.
(10) Remove viscous fan/drive assembly (Refer to 7
- COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(11) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(12) Remove the cooling fan support/hub from the
front of the engine.
(13) Raise the vehicle on hoist.
(14) Remove the crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL) and speed indicator ring.
(15) Lower the vehicle.
(16) Remove the hydraulic pump.
(17) Remove the accessory drive belt tensioner.
(18) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the gasket surfaces.
(19) Remove the fuel injection pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - REMOVAL).
(20) Disconnect the camshaft position sensor con-
nector.
(21) Disconnect and remove engine speed sensor.
(22) Remove the camshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
(23) Remove the six front oil pan fasteners.
(24) Remove the gear housing fasteners.
NOTE: Use care when removing the gear housing,
to avoid damage to the oil pan gasket, as the gas-
ket will be reused if it is not damaged.
(25) Slide a feeler gauge between the gear housing
and oil pan gasket, to break the gasket seal.
(26) Remove the gear housing and gasket.
9 - 348 ENGINE 5.9L DIESELDR
EXHAUST MANIFOLD (Continued)
Page 1700 of 2895
(2) Remove fuel pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(3) Start and run engine until it stalls.
(4) Attempt restarting engine until it will no
longer run.
(5) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unplug connector from any fuel injector.
(7) Attach one end of a jumper wire with alligator
clips (18 gauge or smaller) to either injector terminal.
(8) Connect other end of jumper wire to positive
side of battery.(9) Connect one end of a second jumper wire to
remaining injector terminal.
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentarily touch other end of jumper wire
to negative terminal of battery for no more than a
few seconds.
(11) Place a rag or towel below fuel line quick-con-
nect fitting at fuel rail.
(12) Disconnect quick-connect fitting at fuel rail.
Refer to Quick-Connect Fittings.
(13) Return fuel pump relay to PDC.
(14) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRBtscan tool must be
used to erase a DTC.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
339 kPa +/- 34 kPa (49.2 psi +/- 2 psi).
TORQUE - FUEL SYSTEM
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Accelerator Pedal Bracket
Mounting12 - 105
Accelerator Pedal Position
Sensor Bracket-to-Battery
Tray Bolts3-30
Crankshaft Position
Sensor - 3.7L28 21 -
Crankshaft Position
Sensor - 4.7L28 21 -
Crankshaft Position
Sensor - 5.7L12 - 105 (+/-20)
Crankshaft Position
Sensor - 5.9L8-70
Crankshaft Position
Sensor - 8.0L8-70
Camshaft Position Sensor
- 3.7L12 - 106
Camshaft Position Sensor
- 4.7L12 - 106
Camshaft Position Sensor
- 5.7L12 9 105 (+/-) 20
Camshaft Position Sensor
- 8.0L6-50
DRFUEL DELIVERY - GAS 14 - 3
FUEL DELIVERY - GAS (Continued)
Page 1730 of 2895
INSTALLATION
(1) Install fuel injector(s) into fuel rail assembly
and install retaining clip(s).
(2) If same injector(s) is being reinstalled, install
new o-ring(s).
(3) Apply a small amount of clean engine oil to
each injector o-ring. This will aid in installation.
(4) Install fuel rail. Refer to Fuel Rail Installation.
(5) Start engine and check for fuel leaks.
FUEL PUMP RELAY
DESCRIPTION
The 5±pin, 12±volt, fuel pump relay is located in
the Power Distribution Center (PDC). Refer to the
label on the PDC cover for relay location.
OPERATION
The Powertrain Control Module (PCM) energizes
the electric fuel pump through the fuel pump relay.
The fuel pump relay is energized by first applying
battery voltage to it when the ignition key is turned
ON, and then applying a ground signal to the relay
from the PCM.
Whenever the ignition key is turned ON, the elec-
tric fuel pump will operate. But, the PCM will shut-
down the ground circuit to the fuel pump relay in
approximately 1±3 seconds unless the engine is oper-
ating or the starter motor is engaged.
REMOVAL
The fuel pump relay is located in the Power Distri-
bution Center (PDC) (Fig. 19). Refer to label on PDC
cover for relay location.
(1) Remove PDC cover.
(2) Remove relay from PDC.
(3) Check condition of relay terminals and PDC
connector terminals for damage or corrosion. Repair
if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
INSTALLATION
The fuel pump relay is located in the Power Distri-
bution Center (PDC). Refer to label on PDC cover for
relay location.
(1) Install relay to PDC.
(2) Install cover to PDC.
IDLE AIR CONTROL MOTOR
DESCRIPTION
A separate IAC motor is not used with the 5.7L V-8
engine.
The IAC stepper motor is mounted to the throttle
body, and regulates the amount of air bypassing the
control of the throttle plate. As engine loads and
ambient temperatures change, engine rpm changes.
A pintle on the IAC stepper motor protrudes into a
passage in the throttle body, controlling air flow
through the passage. The IAC is controlled by the
Powertrain Control Module (PCM) to maintain the
target engine idle speed.
OPERATION
A separate IAC motor is not used with the 5.7L V-8
engine.
At idle, engine speed can be increased by retract-
ing the IAC motor pintle and allowing more air to
pass through the port, or it can be decreased by
restricting the passage with the pintle and diminish-
ing the amount of air bypassing the throttle plate.
The IAC is called a stepper motor because it is
moved (rotated) in steps, or increments. Opening the
IAC opens an air passage around the throttle blade
which increases RPM.
The PCM uses the IAC motor to control idle speed
(along with timing) and to reach a desired MAP dur-
ing decel (keep engine from stalling).
Fig. 19 PDC LOCATION
1 - BATTERY
2 - PDC (POWER DISTRIBUTION CENTER)
DRFUEL INJECTION - GAS 14 - 33
FUEL INJECTOR (Continued)
Page 1762 of 2895
pump. The Fuel Pump/Gear Pump is a low-pressure
pump and produce pressures ranging from 551.5 kpa
(80 psi) to 1241 kpa (180) psi. Fuel then enters the
fuel injection pump. Low pressure fuel is then sup-
plied to the FAC (Fuel Control Actuator).
The FAC is an electronically controlled solenoid
valve. The ECM controls the amount of fuel that
enters the high-pressure pumping chambers by open-
ing and closing the FAC based on a demanded fuel
pressure. The FPS (Fuel Pressure Sensor) on the fuel
rail provides the actual fuel pressure. When the
actuator 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 tank through the
drain manifold.
Fuel entering the injection pump is pressurized to
between 300 - 1600 bar by three radial pumping
chambers. The pressurized fuel is then supplied to
the fuel rail.
DIAGNOSIS AND TESTING - FUEL INJECTION
PUMP TIMING
With the Bosch injection pump, there are no
mechanical adjustments needed or necessary to
accomplish fuel injection timing. All timing and fuel
adjustments are electrically made by the engine
mounted Engine Control Module (ECM).
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. Cover and isolate ends of both cables.
(2) Remove intake manifold air intake tube (above
injection pump) and its rubber connector hose (Fig.
8).
(3) The Engine Control Module (ECM) is mounted
to left side of engine (Fig. 9). Remove 5 ECM mount-ing bolts and position ECM for injection pump
removal.Do not disconnect wiring connectors
from ECM.
(4) Remove cooling fan shroud.
(5) Remove cooling fan assembly.
(6) Remove accessory drive belt.
(7) Thoroughly clean the rear of injection pump,
and attachment points for its 3 fuel lines (Fig. 10).
Also clean the opposite ends of these same 3 lines at
their attachment points.
(8) Disconnect Fuel Control Actuator (FCA) electri-
cal connector at rear of injection pump (Fig. 11).
(9) Remove fuel line (injection pump-to-overflow
valve).
(10) Remove fuel line (injection pump-to-fuel rail).
(11) Remove fuel line (injection pump-to-fuel filter
housing).
(12) Remove fuel pump drive gear access cover
(plate) with a 1/2 inch drive ratchet. Plate is
threaded to timing gear cover (Fig. 12).
(13) Remove fuel pump drive gear mounting nut
and washer.
(14) Attach C3428B, or L4407A (or equivalent)
gear puller (Fig. 13) to pump drive gear with 2 bolts,
and separate gear from pump (a keyway is not used
on this particular injection pump). Leave drive gear
hanging loose within timing gear cover.
(15) Remove 3 injection pump mounting nuts (Fig.
14), and remove pump from engine.
Fig. 8 INTAKE TUBE AND CONNECTING HOSE
1 - MANIFOLD ABOVE HEATERS
2 - RUBBER CONNECTING HOSE
3 - METAL INTAKE TUBE
4 - CLAMPS (2)
DRFUEL DELIVERY - DIESEL 14 - 65
FUEL INJECTION PUMP (Continued)
Page 1779 of 2895
INSTALLATION
Early Diesel Engines
The APPS is serviced (replaced) as one assembly
including the lever, brackets and sensor. The APPS is
calibrated to its mounting bracket.
(1) Snap electrical connector into bottom of sensor.
(2) Position APPS assembly to engine and install 6
bolts. Tighten bolts to 24 N´m (18 ft. lbs.) torque.
(3) Connect wiring harness clip 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 have secured cable.
(6) Install throttle cable into mounting bracket. Be
sure pinch tabs 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 bedone (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 III scan tool to erase any DTC's
from ECM.
Late Diesel Engines
(1) Install Accelerator Pedal Position Sensor
(APPS) cable to accelerator pedal. Refer to Accelera-
tor Pedal Removal / Installation.
(2) Connect electrical connector to APPS.
(3) If necessary, connect cable to APPS lever ball
socket (snaps on).
(4) Snap APPS cable cover closed.
(5) Position APPS assembly to bottom of battery
tray and install 3 bolts. Refer to Torque Specifica-
tions.
(6) Install wheelhouse liner. Refer to Body.
(7) Perform the following procedure:
(a) Connect negative battery cables to both bat-
teries.
(b) Turn key switch ON, but do not crank
engine.
(c) Leave key switch ON for a minimum of 10
seconds. This will allow ECM to learn electrical
parameters.
(8) If necessary, use DRB IIItScan Tool to erase
any Diagnostic Trouble Codes (DTC's) from PCM.CAMSHAFT POSITION
SENSOR
DESCRIPTION
The Camshaft Position Sensor (CMP) on the 5.9L
diesel engine is located below the fuel injection
pump. It is bolted to the back of the timing gear
cover.
OPERATION
The diesel Camshaft Position Sensor (CMP) con-
tains a hall effect device. A rotating target wheel
(tonewheel) for the CMP is located on the front tim-
ing gear. This hall effect device detects notches
located on the tonewheel. As the tonewheel rotates,
the notches pass the tip of the CMP.
When the leading edge of the tonewheel notch
passes the tip of the CMP, the following occurs: The
interruption of magnetic field causes the voltage to
switch high resulting in a signal of approximately 5
volts.
When the trailing edge of the tonewheel notch
passes the tip of the CMP, the following occurs: The
change of the magnetic field causes the signal voltage
to switch low to 0 volts.
Fig. 7 APPS CABLE (LATE)
1 - APPS LEVER
2 - BALL SOCKET
3 - SWING-DOWN DOOR
4 - CABLE CLIP
5 - CABLE
14 - 82 FUEL INJECTION - DIESELDR
ACCELERATOR PEDAL POSITION SENSOR (Continued)