apps DODGE RAM 2003 Service Repair Manual

ENGINE CONTROL MODULE
DESCRIPTION - ECM
The Engine Control Module (ECM) is bolted to the
left side of the engine below the intake manifold (Fig.
2).
OPERATION - ECM
The main function of the Engine Control Module
(ECM) is to electrically control the fuel system. The
Powertrain Control Module (PCM)does not control
the fuel system.
The ECM can adapt its programming to meet
changing operating conditions.If the ECM has
been replaced, flashed or re-calibrated, the
ECM must learn the Accelerator Pedal Position
Sensor (APPS) idle voltage. Failure to learn
this voltage may result in unnecessary diagnos-
tic trouble codes. Refer to ECM Removal/Instal-
lation for learning procedures.
The ECM receives input signals from various
switches and sensors. Based on these inputs, the
ECM regulates various engine and vehicle operations
through different system components. These compo-
nents are referred to asECM Outputs.The sensors
and switches that provide inputs to the ECM are
consideredECM Inputs.NOTE: ECM Inputs:
²Accelerator Pedal Position Sensor (APPS) Volts
²APPS1 Signal Ð For off engine APPS
²APPS2 Signal Ð For off engine APPS
²APPS Idle Validation Switches #1 and #2
²Battery voltage
²Camshaft Position Sensor (CMP)
²CCD bus (+) circuits
²CCD bus (-) circuits
²Crankshaft Position Sensor (CKP)
²Data link connection for DRB scan tool
²Engine Coolant Temperature (ECT) sensor
²Ground circuits
²Fuel Pressure Sensor
²Battery Temperature
²Fan speed
²Inlet Air Temperature Sensor/Pressure Sensor
²Intake Air Temperature Sensor/MAP Sensor
²Oil Pressure SWITCH
²Power ground
²Sensor return
²Signal ground
²Water-In-Fuel (WIF) sensor
NOTE: ECM Outputs:
After inputs are received by the ECM, certain sen-
sors, switches and components are controlled or reg-
ulated by the ECM. These are consideredECM
Outputs.These outputs are for:
²CCD bus (+) circuits
²CCD bus (-) circuits
²CKP and APPS outputs to the PCM
²Data link connection for DRB scan tool
²Five volt sensor supply
²Fuel transfer (lift) pump
²Intake manifold air heater relays #1 and #2 con-
trol circuits
²Malfunction indicator lamp (Check engine lamp)
(databus)
²Oil Pressure Swith/warning lamp (databus)
²Fuel Control Actuator
²Wait-to-start warning lamp (databus)
²Fan Clutch PWM
²Water-In-Fuel (WIF) warning lamp (databus)
REMOVAL
The Engine Control Module (ECM) is bolted to a
support bracket near the fuel filter. The support
bracket mounts to the block with four capscrews and
vibration isolators. A ground wire is fastened to the
bracket. The other end of the wire is fastened to the
engine block.
(1) Record any Diagnostic Trouble Codes (DTC's)
found in the ECM.
Fig. 2 DIESEL ECM
1 - ENGINE CONTROL MODULE (ECM)
2 - ECM MOUNTING BOLT
3 - 50-WAY CONNECTOR
4 - SUPPORT PLATE
5 - 60-WAY CONNECTOR
8E - 4 ELECTRONIC CONTROL MODULESDR

A/C-HEATER CONTROL C1 - BLACK 16 WAY
CAV CIRCUIT FUNCTION
1 F15 20DB FUSED IGNITION SWITCH OUTPUT (RUN)
2 Z120 20WT/BK GROUND
3 C57 20DB/GY SENSOR GROUND
4 C33 20DB/RD MODE DOOR 2 DRIVER
5- -
6 C12 20LG/BK EVAPORATOR TEMPERATURE SENSOR SIGNAL
7- -
8 Y165 20OR/YL PANEL LAMPS DRIVER
9 C62 20DB/PK BLEND DOOR DRIVER
10 C35 20DG/YL MODE DOOR 1 DRIVER
11 C34 20DB/WT COMMON DOOR DRIVER
12 C32 20GY/DB RECIRCULATION DOOR DRIVER
13 C46 20YL/LG PASSENGER BLEND DOOR DRIVER
14 - -
15 C16 20LB/YL HEATED MIRROR RELAY CONTROL
16 D25 20VT/LG PCI BUS
A/C-HEATER CONTROL C2 - BLACK 10 WAY
CAV CIRCUIT FUNCTION
1- -
2 C4 16TN BLOWER MOTOR LOW DRIVER
3 C6 14LB BLOWER MOTOR M2 DRIVER
4- -
5 Z37 10BK/DB GROUND
6- -
7 C5 16LG BLOWER MOTOR M1 DRIVER
8- -
9- -
10 C7 10BK/TN BLOWER MOTOR HIGH DRIVER
ACCELERATOR PEDAL POSITION SENSOR (5.7L/DIESEL M/T NORMAL BUILD)-6WAY
CAV CIRCUIT FUNCTION
1 K81 20DB/DG APPS NO. 2 SIGNAL
2 K6 20VT/WT 5-VOLT SUPPLY
3 K7 20OR 5-VOLT SUPPLY
4 K981 20BR/DG APPS NO. 2 RETURN
5 K255 20WT/DG APPS NO. 1 SIGNAL
6 K223 20PK/DB APPS NO. 1 RETURN
8W - 80 - 6 8W-80 CONNECTOR PIN-OUTSDR

ELECTRONIC THROTTLE CONTROL MODULE (5.7L) - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 K22 18OR/DB TP NO.1 SIGNAL
2 K7 18OR 5 VOLT SUPPLY
3 F888 18BR/PK ETC MOTOR(+)
4 K122 18DB/GY TP NO.2 SIGNAL
5 F855 18OR/PK ETC MOTOR(-)
6 K101 18WT TP SENSOR RETURN
ENGINE CONTROL MODULE - C1 (DIESEL) - 60 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3- -
4 D1 18VT/BR CCD BUS (+)
5 D2 18WT/BK CCD BUS (-)
6 K65 18OR/RD FUEL PUMP SUPPLY
7 K20 18DG GENERATOR FIELD CONTROL
8- -
9- -
10 - -
11 - -
12 K102 18PK/BK FUEL PRESSURE SENSOR SIGNAL
13 - -
14 K232 18YL APPS SIGNAL
15 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
16 - -
17 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
18 - -
19 K31 18BR FUEL PUMP RELAY CONTROL
20 - -
21 - -
22 G17 18WT/TN SPEEDOMETER SIGNAL
23 K104 18RD/WT SENSOR GROUND
24 K53 18DB/RD HALL EFFECT
25 Y501 18DB/YL 5 VOLT SUPPLY
26 C18 18DB A/C PRESSURE SIGNAL
27 K6 18VT/WT 5 VOLT SUPPLY
28 - -
29 Y502 18DG/YL INLET AIR TEMPERATURE/PRESSURE RETURN
30 K118 16WT/DB BATTERY TEMPERATURE SENSOR SIGNAL
31 G20 18VT/YL IGNITION SWITCH SENSE
32 K55 18LB/WT MASS AIR FLOW SENSOR SIGNAL
33 K56 18LG/OR APPS SENSOR RETURN
34 K49 18VT/BK APPS IDLE SWITCH
35 - -
36 K14 16RD/WT FUEL INJECTOR NO. 4 DRIVER
37 - -
8W - 80 - 54 8W-80 CONNECTOR PIN-OUTSDR

ENGINE CONTROL MODULE - C1 (DIESEL) - 60 WAY
CAV CIRCUIT FUNCTION
38 - -
39 - -
40 K13 16TN FUEL INJECTOR NO. 3 DRIVER
41 - -
42 K900 18DB/DG 5 VOLT SUPPLY
43 K9 18LB 5 VOLT SUPPLY
44 K101 18WT APPS NOT IDLE SWITCH
45 K62 18BR/DB LETF PUMP
46 K58 16BR/DB FUEL INJECTOR NO. 6 DRIVER
47 - -
48 - -
49 - -
50 K12 16YL/WT FUEL INJECTOR NO. 2 DRIVER
51 - -
52 K167 18BR/YL ACCELERATOR PEDAL POSITION SENSOR GROUND
NO. 1
53 G910 18VT/RD FUEL PRESSURE SENSOR SIGNAL RETURN
54 K72 18DG/OR MAP SENSOR SIGNAL
55 - -
56 K38 16GY FUEL INJECTOR NO. 5 DRIVER
57 K92 16TN/PK COIL ON PLUG DRIVER NO. 2
58 - -
59 K91 16TN/RD COIL ON PLUG DRIVER NO. 1
60 - -
ENGINE CONTROL MODULE - C2 (DIESEL) - 50 WAY
CAV CIRCUIT FUNCTION
1 K22 18DR/DB THROTTLE POSITION SENSOR SIGNAL
2 K24 18WT/DG CRANKSHAFT POSITION SENSOR SIGNAL
3 K69 18 BR/LB INJECTOR CONTROL SIGNAL NO.1
4- -
5 K154 18GY GLOW PLUG RELAY NO. 1 OUTPUT
6 K152 18WT GLOW PLUG RELAY NO. 1 CONTROL
7- -
8- -
9- -
10 Y5 18OR FAN SPEED SENSOR
11 G7 18WT/OR VEHICLE SPEED SIGNAL
12 G60 18GY/YL ENGINE OIL PRESSURE SWITCH SENSE
13 - -
14 - -
15 - -
16 D21 18PK SCI TRANSMIT
17 - -
18 - -
19 D20 18LG SCI RECEIVE
20 A140 16DG/WT FUSED B(+)
21 Z816 16BK/TN GROUND
22 - -
23 Y3 18WT -
24 K4 18BK/LB SENSOR GROUND
25 - -
26 G8 18 LB/BK FUEL LEVEL SENSOR SIGNAL
27 K77 18 BR/WT TRANSFER CASE POSITION SENSOR INPUT
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55

POWERTRAIN CONTROL MODULE C3 (NGC) - WHITE 38 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3 K51 20DB.YL ASD RELAY CONTROL
4- -
5 V35 18LG/RD (4.7L) S/C VENT CONTROL
6 Y145 20DB/YL CONDENSER FAN RELAY CONTROL
7 V32 20YL/RD (4.7L) S/C POWER SUPPLY
8 K106 18WT/DG (4.7L) NVLD SOLENOID CONTROL
9 K199 18BR/VT O2 1/2 HEATER CONTROL
10 K399 18BR/GY (4.7L) O2 2/2 HEATER CONTROL
11 C13 20DB/OR A/C CLUTCH RELAY CONTROL
12 V36 18TN/RD (4.7L) S/C VACUUM CONTROL
13 - -
14 V32 20YL/RD (5.7L) BRAKE SWITCH NO.2 SIGNAL
15 Y215 20YL/PK (5.7L) S/C SWITCH RETURN
16 K223 18PK/DB (5.7L) APPS NO.1 RETURN
17 K981 18BR/DG (5.7L) APPS NO.2 RETURN
18 V38 20VT/OR (5.7L) S/C SWITCH NO.2 SIGNAL
19 A142 16DG/OR ASD RELAY OUTPUT
20 K108 18WT/TN EVAP PURGE SOL SIGNAL
21 T24 20BR/YL TRS T24 SENSE (P/N SENSE)
22 G113 18OR PTO SWITCH SENSE
23 K29 18WT/PK BRAKE SWITCH SIGNAL
24 - -
25 K255 18WT/DG (5.7L) APPS NO.1 SIGNAL
26 - -
27 - -
28 A142 16DG/OR ASD RELAY OUTPUT
29 K52 18PK/BK EVAP PURGE SOL CONTROL
30 S28 18YL/BK P/S SWITCH SIGNAL
31 - -
32 K118 18PK/YL BATT TEMP SIGNAL
33 G8 18LB/BK FUEL LEVEL SIGNAL
34 V37 18RD/LG S/C SWITCH NO.1 SIGNAL
35 K107 18OR NVLD SWITCH SIGNAL
36 K81 18DB/DG (5.7L) APPS NO.2 SIGNAL
37 K31 18BR FUEL PUMP RELAY CONTROL
38 T752 18DG/OR STARTER RELAY CONTROL
8W - 80 - 92 8W-80 CONNECTOR PIN-OUTSDR

POWERTRAIN CONTROL MODULE C4 (NGC) - GREEN 38 WAY
CAV CIRCUIT FUNCTION
1 T60 18BR (4.7L) OVERDRIVE SOLENOID CONTROL
2 T159 18DG/WT (4.7L) 4C SOLENOID CONTROL
3 Y207 18RD/WT (5.7L) TPS NO. 1 OUTPUT
4 T140 18VT/LG (4.7L) PRESSURE CONTROL SOLENOID CONTROL
5 Y208 18DB/YL (5.7L) APPS NO. 1 OUTPUT
6 T119 18WT/DB (4.7L) 2C SOLENOID CONTROL
7 T10 18YL/DG (5.7L) TORQUE MANAGEMENT REQUEST SENSE
8 T59 18PK (4.7L) UNDERDRIVE SOLENOID CONTROL
9 Y209 18TN/BK (5.7L) SENSOR GROUND
10 T120 18LG (4.7L) LR SOLENOID CONTROL
11 T118 18YL/DB (4.7L) PRESSURE CONTROL SOLENOID CONTROL
11 Y210 18YL/RD (5.7L EATX) RPM SIGNAL
12 Z13 16BK/RD (4.7L) GROUND
13 Z13 16BK/RD (4.7L) GROUND
14 Z13 16BK/RD (4.7L) GROUND
15 T1 18LG/BK (4.7L) TRS T1 SENSE
16 T3 18VT (4.7L) TRS T3 SENSE
17 T6 18OR/WT (4.7L) OVERDRIVE OFF SWITCH SENSE
18 K30 18PK (4.7L) TRANSMISSION CONTROL RELAY CONTROL
19 T16 16RD (4.7L) TRANSMISSION CONTROL RELAY OUTPUT
20 T48 18DB (4.7L) 4C PRESSURE SWITCH SENSE
21 T29 18GY (4.7L) UNDERDRIVE PRESSURE SWITCH SENSE
22 T9 18OR/BK (4.7L) OVERDRIVE PRESSURE SWITCH SENSE
23 - -
24 - -
25 - -
26 T4 18PK/OR (4.7L) TRS T2 SENSE
27 - -
28 T16 16RD (4.7L) TRANSMISSION CONTROL RELAY OUTPUT
29 T50 18DG (4.7L) LOW/REVERSE PRESSURE SWITCH SENSE
30 T147 18LB (4.7L) 2C PRESSURE SWITCH SENSE
31 T38 18VT/TN (4.7L) LINE PRESSURE SENSOR SIGNAL
32 T14 18LG/WT (4.7L) OUTPUT SPEED SENSOR SIGNAL
33 T52 18RD/BK (4.7L) INPUT SPEED SENSOR SIGNAL
34 T13 18DB/BK (4.7L) SPEED SENSOR GROUND
35 T54 18VT (4.7L) TRANSMISSION TEMPERATURE SENSOR SIGNAL
36 - -
37 T42 18VT/WT (4.7L) TRS T42 SENSE
38 T16 16RD (4.7L) TRANSMISSION CONTROL RELAY OUTPUT
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 93

TRANSMISSION CONTROL MODULE - BLACK 60 WAY
CAV CIRCUIT FUNCTION
1 T1 18LG/BK TRS T1 SENSE
2 T4 18PK/OR TRS T2 SENSE
3 T3 18VT TRS T3 SENSE
4- -
5- -
6 Y210 18YL/RD (5.7L) EATX RPM SIGNAL
6 K24 18GY/BK (3.7L) CRANKSHAFT POSITION SENSOR SIGNAL
7 D15 18WT/DG SCI TRANSMIT (TCM)
8 A41 16YL FUSED IGNITION SWITCH OUTPUT (START)
9 T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE
10 T10 18YL/DG TORQUE MANAGEMENT REQUEST SENSE
11 A51 16RD/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 Y208 18DB/YL (5.7L) APPS NO.1 OUTPUT
12 K22 18OR/DB (3.7L) THROTTLE POSITION SENSOR SIGNAL
13 T13 18DB/BK SPEED SENSOR GROUND
14 T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL
15 K30 19PK TRANSMISSION CONTROL RELAY CONTROL
16 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
17 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
18 T118 18YL/DB PRESSURE CONTROL SOLENOID CONTROL
19 T119 18WT/DB 2C SOLENOID CONTROL
20 T120 18LG LR SOLENOID CONTROL
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 B22 20DG/YL (5.7L) VEHICLE SPEED SIGNAL
28 G7 18WT/OR (3.7L) VEHICLE SPEED SIGNAL
29 T29 18GY UNDERDRIVE PRESSURE SWITCH SENSE
30 T38 18VT/TN LINE PRESSURE SENSOR SIGNAL
31 - -
32 - -
33 - -
34 - -
35 - -
36 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
37 Z13 16BK/RD GROUND
38 T39 18GY/LB 5 VOLT SUPPLY
39 Z13 16BK/RD GROUND
40 T140 18VT/LG MS SOLENOID CONTROL
41 T41 18BK/WT TRS T41 SENSE(C1)
42 T42 18VT/WT TRS T42 SENSE
43 D25 20VT/OR PCI BUS
44 - -
45 Y207 18RD/WT (5.7L) TPS NO.1 OUTPUT
46 D6 18PK/LB SCI TRANSMIT
47 T147 18LB 2C PRESSURE SWITCH SENSE
48 T48 18DB 4C PRESSURE SWITCH SENSE
49 T6 20OR/WT OVERDRIVE OFF SWITCH SENSE
50 T50 18DG LOW/REVERSE PRESSURE SWITCH SENSE
51 Y209 18TN/BK (5.7L) SENSOR GROUND
51 K4 18BK/LB (3.7L) SENSOR GROUND
8W - 80 - 104 8W-80 CONNECTOR PIN-OUTSDR

(35) Remove the passenger battery ground cable
from the engine block. Remove the driver side bat-
tery ground cable from the engine block.
(36) Remove power steering pump from engine by
removing 3 bolts.
(37) Remove accelerator linkage cover.
(38)
Disconnect cables from APPS if early model build
(39) If late model build,
(40) Disconnect the ECM power connector.
(41) Disconnect the ECM ground wire from the
hydroform screw.
(42) Disconnect the fuel supply and return hoses.
(43) Remove the cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(44) Disconnect the 3 injector harness connectors
at the rocker housing. Disconnect the wire harnesses
from the injectors.
(45) Remove the rear engine lift bracket.
(46) Remove cylinder #4, #5, and #6 intake and
exhaust rocker arms, pedestals, and push tubes. Note
the original location for re-assembly.
(47) Loosen #6 fuel line shield bolts and rotate
shield out of the way.
(48)
Remove cylinder #5 and #6 high pressure fuel
lines. Remove the fuel connector tube nut and fuel con-
nector tube. 46. Remove cylinder #5 and #6 fuel injector.
(49) Remove rocker housing.
(50) Remove two cylinder head bolts in location 4
and 12 according to the diagram below and install
Tool # 9009 (Fig. 3).(51) Loosen but do not remove engine mount
through bolts and nuts.
(52) Disconnect hood support struts and position
hood out of the way.
(53) Attach a chain with two hooks to the engine
lift brackets.
(54) While keeping engine level, lift straight up
out of the mounts.
(55) Rotate nose of engine upward and pull out of
chassis.
REMOVALÐCRANKCASE BREATHER
(1) Remove the oil fill cap.
(2) Remove the breather cover bolts (Fig. 4).
(3) Remove breather cover.
(4) Disconnect breather tube and lube oil drain
tube from breather.
(5) Remove breather mounting bolts.
(6) Remove breather from cylinder head cover.
INSTALLATION
INSTALLATIONÐENGINE
(1) Remove cylinder head bolts in locations 4 and
12 according to the diagram below. Install special
Tool 9009.Fig. 3 ENGINE LIFT BRACKET
1 - Head bolt
2 - Engine Lift Bracket
3 - Head Bolt
Fig. 4 Crankcase Breather Vapor Canister
1 - BREATHER COVER BOLT
2 - BREATHER COVER
3 - BREATHER TUBE
4 - ROCKER COVER
5 - BREATHER TUBE MOUNTING BRACKET
6 - LUBE OIL DRAIN TUBE
7 - O-RING
8 - BREATHER
9- BREATHER MOUNTING BOLT
DRENGINE 5.9L DIESEL 9 - 291
ENGINE 5.9L DIESEL (Continued)

(2) Lower engine into the engine compartment and
install the engine the engine mount through bolts
and nuts.
(3) Tighten the mount through bolts and nuts to
88 N-m (65 ft-lbs) torque.
(4) Remove the engine lifting device (Tool 9009).
(5) Check cylinder head capscrew length and
install into cylinder head.
(6) Torque alternately to 70 N-m (52 ft-lbs). Torque
alternately to 105 N-m (77 ft-lbs). Rotate 90 degrees.
(7) Install rocker housing. Torque to 24 N-m (18 ft-
lbs). Refer to Section 9 Rocker Housing Installation
(8) Replace injector o-ring and sealing washer on
injectors #5 and #6. Install injectors and alternately
tighten hold-down capscrews to 10 N-m (89 in-lbs).
(9) Install fuel connector tube and fuel connector
tube nut. Torque to 50 N-m (37 ft-lb). 10.
(10) Install #5 and #6 high pressure fuel lines. Fol-
low correct torque sequence per section 14. Torque
fuel line fittings to 30 N-m (22 ft-lb). Torque brace
capscrew to 24 N-m (18 ft-lb).
(11) Install rear engine lift bracket. Torque to 77
N-m (57 ft-lb).
(12) Install push tubes, rocker arms, and pedestals
for cylinders #4, #5, and #6. Torque the mounting
bolts to 36 N-m (27 ft-lbs).
(13) Reset valve lash on cylinders #4, #5, and #6.
Torque adjusting nuts to 24 N-m (18 ft-lbs).
(14) Install cylinder head cover. Torque to 24 N-m
(18 ft-lbs).(Refer to 9 - ENGINE/CYLINDER HEAD -
INSTALLATION).
(15) Connect breather tube and lube oil drain tube
to breather housing. Install breather housing. Torque
capscrews to 24 N-m (18 ft-lbs)
(16) Connect fuel supply and return hoses.
(17) Connect ECM ground to hydroform screw.
Connect ECM power connector.
(18) Install the APPS cable(s) to the APPS. Install
the throttle linkage cover.
(19) Install the power steering pump.
(20) Install the damper and speed indicator ring.
Torque to 40 N-m (30 ft-lb) plus 60 degrees.
(21) Connect the engine block heater connection.
(22) Connect the A/C compressor and pressure sen-
sor connectors
(23) Install the charge air cooler and a/c condenser
(if equipped). Install and tighten the charge air
cooler mounting bolts to 2 N-m (17 in-lbs).
(24) Connect the charge air cooler piping. Torque
all clamps to 8 N-m (72 in-lbs).
(25) Connect the a/c refrigerant lines to the a/c
condenser (if equipped).
(26) Install the radiator upper support panel.
(27) Install radiator.
(28) Connect the transmission quick-connect oil
cooler lines.(29) Raise vehicle.
(30) Connect a/c compressor suction/discharge hose
(if equipped).
(31) Install the radiator lower hose and clamps.
(32) Install the battery negative cables to the
engine block on the driver and passenger side.
(33) Install the transmission adapter with a new
camshaft rectangular ring seal. Torque to 77 N-m (57
ft-lb).
(34) Install the flywheel/flexplate. Torque to 137
N-m (101 ft-lb).
(35) Install the starter motor. Torque to 43 N-m
(32 ft-lb). (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(36) Connect engine to vehicle harness connectors.
(37) Install transmission and transfer case (if
equipped).
(38) Connect the exhaust pipe to the turbocharger
elbow.
(39) Connect the transmission auxiliary oil cooler
lines (if equipped).
(40) Lower the vehicle.
(41)
Connect the heater core supply and return hoses.
(42) Install the cooling fan and upper fan shroud
at the same time. (Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - INSTALLATION).
(43) Install the coolant recovery bottle.
(44) Install the windshield washer bottle.
(45) Install the upper radiator hose and clamps.
(46) Raise vehicle.
(47) Connect electronically controlled fan drive
wire harness. Install lower radiator fan shroud.
(48) Change oil filter and install new engine oil.
(49) Fill the cooling system with coolant. (Refer to
7 - COOLING - STANDARD PROCEDURE).
(50) Connect grid heater harness at grid heater
relays.
(51) Connect electrical connections to rear of alter-
nator.
(52) Start the engine and inspect for engine oil,
coolant, and fuel leaks.
INSTALLATIONÐCRANKCASE BREATHER
(1) Install a new o-ring onto the breather element.
(2) Lubricate o-ring and install into cylinder head
cover. Torque capscrews to 10 N´m (89 in. lbs.).
(3) Connect breather tube and lube oil drain tube.
(4) Install breather cover (Fig. 4). Torque to 24
N´m (18 ft. lbs.)
(5) Install oil fill cap.
9 - 292 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

ENGINE DATA PLATE
DESCRIPTION
The engine data plate contains specific information
that is helpful to servicing and obtaining parts for the
engine. The data plate can be found in two places. Some
models have a data plate is located on the left side of
the engine, affixed to the APPS bracket. Some models
will have the data plate affixed to the breather cover on
the left side of the engine. Information that can be
found on the data plate includes:
²Date of Engine Manufacture
²Engine Serial Number
²Control Parts List (CPL)
²Engine Rated Horsepower
²Engine Firing Order
²Engine Displacement
²Valve Lash Reset Specifications
If the engine data plate is missing or not legible,
the engine serial number is used for engine identifi-
cation. The engine serial number is stamped on the
right side of the block, on top of the oil cooler cavity
(Fig. 5).
AIR CLEANER ELEMENT
REMOVAL
Testing Air Cleaner Element using Filter MinderŸ
Do not attempt to unnecessarily remove top
of air cleaner housing for air cleaner element
inspection on diesel engines.
The air cleaner (filter) housing is equipped with an
air Filter MinderŸ gauge (Fig. 6). This air flow
restriction gauge will determine when air cleaner ele-
ment is restricted and should be replaced.
The Filter MinderŸ consists of a diaphragm and
calibrated spring sealed inside of a plastic housing
(Fig. 7). A yellow colored disc attached to diaphragm
moves along a graduated scale on side of Filter
Minder. After engine has been shut off, a ratcheting
device located within Filter Minder will hold yellow
disc at highest restriction that air cleaner elementhas experienced. A drop in air pressure due to an air
cleaner element restriction moves diaphragm and
yellow disc will indicate size of air drop.
CAUTION: Certain engine degreasers or cleaners
may discolor or damage plastic housing of Filter
Minder. Cover and tape Filter Minder if any engine
degreasers or cleaners are to be used.
To test, turn engine off. If yellow disc (Fig. 7) has
reached red colored zone on graduated scale, air cleaner
element should be replaced. Refer to Removal / Instal-
lation.
Resetting Filter Minder:After air cleaner (filter)
element has been replaced, press rubber button on
top of Filter Minder (Fig. 7). This will allow yellow
colored disc to reset. After button has been pressed,
yellow disc should spring back to UP position.
If Filter Minder gauge has reached red colored
zone, and after an examination of air cleaner (filter)
element, element appears to be clean, high reading
may be due to a temporary condition such as snow
build-up at air intake. Temporary high restrictions
may also occur if air cleaner (filter) element has got-
ten wet such as during a heavy rain or snow. If this
occurs, allow element to dry out during normal
engine operation. Reset rubber button on top of Filter
Minder and retest after element has dried.
Fig. 5 Engine Serial Number Location
Fig. 6 5.9L DIESEL AIR CLEANER - FILTER
MINDERŸ
1 - CLIPS
2 - FILTER COVER
3 - FILTER MINDERŸ
4 - INLET AIR TEMPERATURE/ PRESSURE SENSOR
5 - FILTER HOUSING
DRENGINE 5.9L DIESEL 9 - 297