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OPERATION
The fuel tank module on diesel powered models has 3 different circuits (wires). Two of these circuits are used at the fuel gauge sending unit for fuel gauge operation. The other wire is used for a ground. The diesel engine does not have a fuel tank module mounted electric fuel pump. The electric fuel pump (fuel transfer pump) is mounted to the engine.
For Fuel Gauge Operation: A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge send- ing unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic pur- poses, this 12V power source can only be veri- fied with the circuit opened (fuel tank module electrical connector unplugged). With the con- nectors plugged, output voltages will vary from about .6 volts at FULL, to about 7.0 volts at EMPTY. The resistor track is used to vary the volt- age (resistance) depending on fuel tank float level. As fuel increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the ECM through the sensor return circuit.
level
Both of the electrical circuits between the fuel gauge sending unit and the ECM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the ECM, the ECM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to Instrument Panel for additional information.
REMOVAL
REMOVAL/INSTALLATION
For diesel removal and installation procedures, refer to the gas section of Fuel System/Fuel Delivery. See Fuel Level Sending Unit/Sensor Removal/Instal- lation.
DR
FUEL LINES DESCRIPTION
Low-Pressure Lines † the fuel supply line from fuel tank to fuel trans- fer (lift) pump. † the fuel return line back to fuel tank. † the fuel drain manifold line at rear of cylinder head.† the fuel supply line from fuel filter to fuel injec- tion pump.
High-Pressure Lines † the fuel line from fuel injection pump to overflow valve.† the fuel line from fuel injection pump to fuel rail.† the 6 fuel lines from fuel rail up to injector con- nector tubes
WARNING: HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS. THIS MAY BE AS HIGH AS 160,000 KPA (23,206
PSI). USE EXTREME CAUTION WHEN INSPECTING FOR HIGH-PRESSURE FUEL LEAKS. INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD. HIGH FUEL INJECTION PRESSURE CAN CAUSE PERSONAL INJURY IF CONTACT IS MADE WITH THE SKIN.OPERATION
High-Pressure Lines
CAUTION: The high-pressure fuel lines must be held securely in place in their holders. The lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. lines are ever kinked or bent, they must be replaced. Use only the recommended lines when replacement of high-pres- sure fuel line is necessary.
If
High-pressure fuel lines deliver fuel (under pres- sure) of up to approximately 160,000 kPa (23,206
PSI) from the injection pump to the fuel injectors. The lines expand and contract from the high-pres- sure fuel pulses generated during the injection pro- cess. 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.FUEL DELIVERY - DIESEL
14 - 69
EXTREME CAUTION WHEN WARNING: USE INSPECTING FOR HIGH-PRESSURE FUEL LEAKS. INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD. HIGH FUEL INJECTION PRESSURE CAN CAUSE PERSONAL INJURY IF CONTACT IS MADE WITH THE SKIN.
DIAGNOSIS AND TESTING - HIGH-PRESSURE FUEL LINE LEAKS
High-pressure fuel line leaks can cause starting
problems and poor engine performance.
WARNING: DUE TO EXTREME FUEL PRESSURES OF UP TO 160,000 kPa (23,206 PSI), USE EXTREME CAUTION WHEN INSPECTING FOR HIGH-PRES- SURE FUEL LEAKS. DO NOT GET YOUR HAND OR A FINGER NEAR A SUSPECTED LEAK. INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD. HIGH FUEL INJECTION PRES- SURE CAN CAUSE PERSONAL INJURY IF CON- TACT IS MADE WITH THE SKIN.
Start the engine. Move the cardboard (Fig. 15) over the suspected high-pressure fuel line leak, and check for fuel spray onto the cardboard. If line is leaking, retorque line. Replace damaged, restricted or leaking high-pressure fuel lines with the correct replacement line.
CAUTION: The high-pressure fuel lines must be clamped securely in place in the holders. The lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. Only use the recom- mended lines when replacement of high-pressure fuel line is necessary.
REMOVAL
lines and fuel
CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system com- ponents. This especially includes the fuel injectors, high-pressure 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.
FUEL DELIVERY - DIESEL
14 - 70
FUEL LINES (Continued)DR
(7) Carefully remove each fuel line from engine. Note position of each while removing. Do not bend lines while removing.
Fig.16BRACKET-#6INJECTOR
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.15TYPICALTESTFORLEAKSUSING
CARDBOARD
1 - HIGH-PRESSURE LINE 2 - CARDBOARD 3 - TYPICAL HIGH-PRESSURE FITTING
(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.
Fig.17FUELINJECTORRAIL
1 - FUEL RAIL MOUNTING BOLTS (3) 2 - INSULATED CLAMPS 3 - FUEL INJECTOR RAIL
DR FUEL LINES (Continued)
FUEL DELIVERY - DIESEL
14 - 71
Fig.18HIGHPRESSUREFUELLINES
5 - SEPARATE FITTING (TYPICAL) 6 - CONNECTOR TUBE RETAINER (FITTING) 7 - CONNECTOR TUBE
1 - FUEL INJECTOR 2 - HIGH-PRESSURE LINE 3 - INJECTOR MOUNTING BOLTS 4 - FUEL INJECTOR RAIL
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
(11) Prime fuel system. Refer to Fuel System
batteries.
Priming.
(12) Check lines/fittings for leaks.
14 - 72
FUEL DELIVERY - DIESEL
DR
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.
Fig.19FUELPRESSURESENSOR/FUELPRES.
LIMIT.VALVE
1 - ELEC. CONNECTOR 2 - BANJO BOLT 3 - FUEL PRESSURE LIMITING VALVE 4 - FUEL PRESSURE SENSOR 5 - TOP OF INTAKE HEATER MANIFOLD
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, sensor must be 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 VALVE 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).
lines and fuel
CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system com- ponents. This especially includes the fuel injectors, high-pressure 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
(2) Remove banjo bolt (Fig. 20) at banjo fitting. (3) Remove pressure limiting valve from intake
valve.
manifold.
DR FUEL PRESSURE LIMITING VALVE (Continued)
FUEL DELIVERY - DIESEL
14 - 73
(2) If vehicle is equipped with 4 doors and a 6 foot
(short) box, remove left-rear tire/wheel.
(3) Thoroughly clean area at
top of
fuel
tank
around fuel tank module.
(4) Remove rubber cap from auxiliary fitting on
top of tank module (Fig. 21).
(5) Drain fuel tank by attaching drain hose from an approved draining station to auxiliary fitting on top of tank module (Fig. 21).
Fig.20FUELPRESSURESENSOR/FUEL
PRESSURELIMITINGVALVE
1 - ELEC. CONNECTOR 2 - BANJO BOLT 3 - FUEL PRESSURE LIMITING VALVE 4 - FUEL PRESSURE SENSOR 5 - TOP OF INTAKE HEATER MANIFOLD
INSTALLATION
(1) Be sure both top of manifold and limiting valve
(2) Assemble banjo bolt and new sealing washers
(3) Tighten banjo bolt to 24 N·M (17 ft.
lbs.)
are clean.
to limiting valve.
torque.
FUEL TANK DESCRIPTION - DIESEL
The fuel tank is similar to the tank used with gas- oline powered models. The tank is equipped with a separate fuel return line and a different fuel tank module for diesel powered models. A fuel tank mounted, electric fuel pump is not used with diesel powered models. Refer to Fuel Tank Module for addi- tional information.
REMOVAL - DIESEL
Fuel Tank Draining
Due to a one-way check valve installed into the fuel fill opening fitting at the tank, the tank cannot be drained conventionally at the fill cap.
(1) Raise vehicle.
Fig.21FUELTANKMODULE-DIESEL
1 - TOP OF FUEL TANK 2 - AUX. FITTING 3 - ELEC. CONNECTOR 4 - FUEL TANK MODULE (TOP) 5 - LOCKNUT 6 - FUEL SUPPLY LINE 7 - FUEL RETURN LINE
Tank Removal
(1) Loosen clamp and disconnect rubber fuel fill
hose at tank.
(2) Support tank with a hydraulic jack. (3) Remove 2 fuel tank strap nuts (Fig. 22) and
remove both tank support straps.
(4) Carefully lower tank a few inches and discon- nect fuel pump module electrical connector (Fig. 21) at top of tank. To disconnect electrical connector: Push upward on red colored tab to unlock. Push on black colored tab while removing connector.
(5) Disconnect fuel supply and return lines at fuel tank module (Fig. 21). Refer to Quick-Connect Fit- tings for procedures.
(6) Continue to lower tank for removal.
FUEL DELIVERY - DIESEL
14 - 74
FUEL TANK (Continued)(7) If fuel tank is to be replaced, remove fuel tank module from tank. Refer to Fuel Tank Module Removal/Installation procedures.
INSTALLATION - DIESEL
(1) If fuel tank is to be replaced, install fuel tank module into tank. Refer to Fuel Tank Module Remov- al/Installation procedures.
(2) Position fuel tank to hydraulic jack. (3) Raise tank until positioned near body. (4) Connect fuel tank module electrical connector
DR
(6) Continue raising tank until positioned snug to
body.
(7) Install and position both tank support straps. Install 2 fuel tank strap nuts and tighten. Tighten rear strap nut first. Refer to Torque Specifications.
(8) Remove hydraulic jack. (9) Connect rubber fill hose to fuel fill tube and
tighten clamp.
(10) Install tire / wheel (if necessary). (11) Lower vehicle. (12) Fill fuel tank with fuel. (13) Start engine and check for fuel leaks near top
at top of tank.
module.
(5) Connect fuel supply and return lines to tank
of module.
1 - FUEL TANK 2 - STRAP MOUNTING STUDS 3 - VEHICLE FRAME
Fig.22FUELTANKMOUNTING
4 - MOUNTING STRAPS 5 - STRAP NUTS
DR
FUEL DELIVERY - DIESEL
14 - 75
FUEL TANK MODULE DESCRIPTION
An electric fuel pump is not used in the fuel tank module for diesel powered engines. Fuel is supplied by the engine mounted fuel transfer (lift) pump.
The fuel tank module is installed in the top of the fuel tank (Fig. 23). The fuel tank module contains the following components: † Fuel reservoir † A separate in-tank fuel filter † Fuel gauge sending unit (fuel level sensor) † Fuel supply line connection † Fuel return line connection † Auxiliary non-pressurized fitting
locknut and remove locknut (Fig. 24). The fuel tank module will spring up when locknut is removed.
(4) Remove module from fuel tank.
Fig.24LOCKNUTREMOVAL/INSTALLATION-
TYPICALMODULE
1 - SPECIAL TOOL 6856
2 - LOCKNUTINSTALLATION
CAUTION: Whenever the fuel tank module is ser- viced, the rubber gasket must be replaced.
(1) Thoroughly clean locknut and locknut threads
at top of tank.
(2) Using new gasket, carefully position fuel tank
module into opening in fuel tank.
(3) Position locknut over top of fuel tank module.
Install locknut finger tight.
(4) When looking down at tank from drivers side of tank, the fuel line connectors and fuel gauge electri- cal connector should all be pointed to drivers side of vehicle. Rotate and align if necessary before tighten- ing locknut. This step must be performed to pre- vent the module’s float from contacting side of fuel tank.
(5) Tighten locknut to 24 - 44 N·m (18 - 32 ft. lbs.)
(6) Install fuel tank. Refer to Fuel Tank Removal/
torque.
Installation.
FUEL TRANSFER PUMP DESCRIPTION
The fuel transfer pump (fuel lift pump) is attached to the rear of the fuel filter/water separator housing. The 12–volt electric pump is operated and controlled by the Engine Control Module (ECM).
Fig.23FUELTANKMODULE-DIESEL
1 - TOP OF FUEL TANK 2 - AUX. FITTING 3 - ELEC. CONNECTOR 4 - FUEL TANK MODULE (TOP) 5 - LOCKNUT 6 - FUEL SUPPLY LINE 7 - FUEL RETURN LINE
OPERATION
Refer to Fuel Gauge Sending Unit.
REMOVAL
(1) Drain and remove fuel tank. Refer to Fuel
Tank Removal/Installation.
(2) Thoroughly clean area around tank module at
top of tank.
(3) The plastic
is threaded onto fuel tank. Install Special Tool 6856 to
tank module
locknut
fuel
FUEL DELIVERY - DIESEL
14 - 76
FUEL TRANSFER PUMP (Continued) OPERATIONDR
The purpose of the fuel transfer pump is to supply (transfer) a low-pressure fuel source: from the fuel tank, through the fuel filter/water separator and to the fuel injection pump. Here, the low-pressure is raised to a high-pressure by the fuel injection pump for operation of injectors. Check valves within the pump, control direction of fuel flow and prevent fuel bleed-back during engine shut down.
the high-pressure fuel
Maximum current flow to the pump is 5 amperes. With the engine running, the pump has a 100 per- cent duty-cycle with a minimum pressure of 11.5 psi. The transfer pump is self-priming: When the key is first turned on (without cranking engine), the pump will operate for approximately 1/2 second and then shut off. The pump will also operate for up to 25 sec- onds after the starter is engaged, and then disen- gaged and the engine is not running. The pump shuts off immediately if the key is on and the engine stops running.
The fuel volume of the transfer pump will always provide more fuel injection pump requires. Excess fuel is returned from the injection pump through an overflow valve, and then back to the fuel tank.
than the fuel
REMOVAL
The fuel transfer pump (fuel lift pump) is attached to the rear of the fuel filter/water separator housing (Fig. 25).
(1) Drain fuel from fuel filter housing. Refer to Fuel Filter/Water Separator - Removal. See Draining. (2) Disconnect electrical connector (Fig. 25) from
fuel transfer pump.
fuel
(3) Disconnect
tank supply line from fuel transfer pump extension line. Do this at disconnec- tion point at inside of left inner frame rail (Fig. 26). Refer to quick-connect fittings for procedures. The fuel line extension is permanently attached to the transfer pump. Do not attempt to discon- nect fuel line at transfer pump.
(4) Remove 4 pump mounting bolts (hex-allen),
and remove pump from fuel filter housing.
(5) Confirm that
transfer pump o-ring is also
removed from fuel filter housing.
INSTALLATION
(1) Install a new o-ring to fuel transfer pump. (2) Lubricate o-ring and OD of transfer pump inlet
connector.
(3) Position fuel transfer pump onto fuel
filter housing. Do not use mounting bolts to draw transfer pump to filter housing.
Fig.25FUELTRANSFER(LIFT)PUMP
1 - FILTER HOUSING 2 - ELEC. CONNECTOR 3 - FUEL TRANSFER (LIFT) PUMP 4 - FUEL LINE EXTENTION 5 - MOUNTING BOLTS (4)
Fig.26TRANSFERPUMPFUELLINECONNECT
1 - LEFT INNER FRAME RAIL 2 - FUEL RETURN LINE 3 - FUEL SUPPLY LINE 4 - QUICK-CONNECT FITTING
DR FUEL TRANSFER PUMP (Continued)
(4) Be sure pump is positioned flat to fuel filter housing. Install mounting bolts and evenly tighten to 7 N·m (61 in. lbs.).
(5) Connect fuel line extension at fuel supply line. (6) Connect electrical connector to pump. (7) Prime System: Cycle key to actuate transfer pump or use DRB II Scan Tool to actuate transfer pump. Check for leaks.
(8) Operate engine and check for fuel leaks.
CASCADE OVERFLOW VALVE DESCRIPTION
The cascade overflow valve is located on the top/
rear side of the fuel injection pump (Fig. 27).
FUEL DELIVERY - DIESEL
14 - 77
REMOVAL
REMOVAL/INSTALLATION
The cascade overflow valve is not serviced sepa-
rately.
WATER IN FUEL SENSOR DESCRIPTION
The Water-In-Fuel (WIF) sensor is located on the side of the fuel filter/water separator canister (Fig. 28), or (Fig. 29).
Fig.28FILTERHOUSING(EARLY)
1 - FILTER HOUSING 2 - FUEL HEATER AND THERMOSTAT 3 - FUEL HEATER MOUNTING SCREWS 4 - FUEL HEATER ELEC. CONNECTOR 5 - DRAIN VALVE 6 - DRAIN VALVE MOUNTING SCREWS 7 - DRAIN HOSE 8 - WIF SENSOR 9 - WIF SENSOR ELEC. CONNECTOR
Fig.27OVERFLOWVALVE
1 - BANJO BOLTS 2 - PUMP MOUNTING NUTS (3) 3 - FUEL INJECTION PUMP 4 - CASCADE OVERFLOW VALVE
OPERATION
When the fuel control actuator (FCA) is opened, the maximum amount of fuel is being delivered to the fuel injection pump. Any fuel that does not enter the injection pump is directed to the cascade overflow valve. The cascade valve regulates how much excess fuel is used for lubrication of the injection pump, and is also used to route excess fuel through the drain circuit and back into the fuel tank.
FUEL DELIVERY - DIESEL
14 - 78
WATER IN FUEL SENSOR (Continued)DR
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
incorporates
The Fuel Drain Circuit
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.29FILTERHOUSING(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
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.
DR
FUEL INJECTION - DIESEL
14 - 79
FUEL INJECTION - DIESEL
TABLE OF CONTENTS
page
page
ACCELERATOR PEDAL POSITION SENSOR
DESCRIPTION
DESCRIPTION (EARLY) DESCRIPTION (LATE)
. . . . . . . . . . . . . . . . 79
. . . . . . . . . . . . . . . . . . 79
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 82CAMSHAFT POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 82
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83CRANKSHAFT POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 83
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84FUEL CONTROL ACTUATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 85
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85FUEL INJECTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 85
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 87FUEL INJECTOR RAIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 89
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 89ACCELERATOR PEDAL POSITION SENSOR
DESCRIPTION
DESCRIPTION (EARLY)
The APPS assembly is located at the top-left-front of the engine. A plastic cover is used to cover the assembly. The actual sensor is located behind its mounting bracket.
DESCRIPTION (LATE)
The Accelerator Pedal Position Sensor (APPS) assembly is located under the vehicle battery tray. A cable connects the assembly to the accelerator pedal.
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 90INLET AIR TEMPERATURE SENSOR/
PRESSURE SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 90
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 90INTAKE AIR HEATER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 91
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 91INTAKE AIR HEATER RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 92
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 93INTAKE AIR TEMPERATURE SENSOR/MAP
SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 93
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 94MAP SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 94
THROTTLE CONTROL CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 96A plastic cover with a movable door is used to cover the assembly.
OPERATION
The Accelerator Pedal Position Sensor (APPS) is a linear potentiometer. It provides the Engine Control Module (ECM) with a DC voltage signal proportional to the angle, or position of the accelerator pedal.
REMOVAL
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. The APPS assem- bly is located at left-front of engine below plastic cable/lever/linkage cover (Fig. 1).
FUEL INJECTION - DIESEL
14 - 80
ACCELERATOR PEDAL POSITION SENSOR (Continued)DR
CAUTION: Do not attempt to remove sensor from its mounting bracket as electronic calibration will be destroyed (sensor-to-bracket mounting screws are permanently attached). Two accelerator lever set screws (Fig. 3) are used to position lever. Do not attempt to alter positions of these set screws as electronic calibration will be destroyed.
(1) Disconnect both negative battery cables at both
batteries.
(2) Remove cable cover (Fig. 1). Cable cover is attached with 2 Phillips screws, 2 plastic retention clips and 2 push tabs (Fig. 1). Remove 2 Phillips screws and carefully pry out 2 retention clips. After clip removal, push rearward on front tab, and upward on lower tab for cover removal.
(3) Using finger pressure only, disconnect end of speed control servo cable from throttle lever pin by pulling forward on connector while holding lever rearward (Fig. 2). DO NOT try to pull connector off perpendicular to lever pin. Connector will be broken.
(4) Using two small screwdrivers, pry throttle cable connector socket from throttle lever ball (Fig. 2). Be very careful not to bend throttle lever arm.
(5) Disconnect transmission control cable at lever
arm (if equipped). Refer to 21, Transmission.
(6) Squeeze pinch tabs on speed control cable (Fig. 2) and pull cable rearward to remove from cable mounting bracket.
(7) Squeeze pinch tabs on throttle cable (Fig. 2) and pull cable rearward to remove from cable mount- ing bracket.
(8) If equipped with an automatic transmission, refer to 21, Transmission for transmission control cable removal procedures.
(9) Disconnect wiring harness clip (Fig. 3) at bot-
tom of bracket.
(10) Remove 6 mounting bolts (Fig. 3) and par- tially remove APPS assembly from engine. After assembly is partially removed, disconnect electrical connector from bottom of sensor by pushing on con- nector tab (Fig. 4).
(11) Remove APPS assembly from engine.
Late Diesel Engines
The APPS is serviced (replaced) as one assembly including the sensor, plastic housing and cable. The APPS assembly is located under the left vehicle bat- tery tray (Fig. 5). Access to APPS is gained from over top of left / front tire.
(1) Disconnect negative battery cable at battery. (2) Disconnect APPS cable at accelerator pedal.
Refer to Accelerator Pedal Removal / Installation.
(3) Remove wheel house liner at left / front wheel.
Refer to Body.
Fig.1CABLE/LEVER/THROTTLELINKAGECOVER 1 - CABLE/LEVER/LINKAGE COVER 2 - PUSH UP LOWER TAB 3 - SCREWS/CLIPS (2) 4 - TAB PUSH HERE
Fig.2SERVOCABLEATTHROTTLELEVER
1 - PINCH (2) TABS 2 - CABLE MOUNTING BRACKET 3 - PINCH TABS (2) 4 - OFF 5 - THROTTLE CABLE 6 - THROTTLE LEVER 7 - THROTTLE LEVER PIN 8 - OFF 9 - CONNECTOR 10 - SPEED CONTROL CABLE
(4) Gain access to APPS electrical connector by opening swing-down door (Fig. 6). Disconnect electri- cal connector.
(5) Remove 3 mounting bolts (Fig. 6). (6) Remove APPS assembly from battery tray.
DR ACCELERATOR PEDAL POSITION SENSOR (Continued)
FUEL INJECTION - DIESEL
14 - 81
Fig.3APPSASSEMBLY
1 - LEVER 2 - MOUNTING BOLTS (6) 3 - WIRE HARNESS CLIP 4 - CALIBRATION SCREWS (NO ADJUSTMENT) 5 - APPS ASSEMBLY
Fig.5APPSLOCATION(LATE)
1 - BATTERY TRAY 2 - APPS LOCATION 3 - APPS MOUNTING BOLTS
Fig.4APPSCONNECTOR
1 - APPS 2 - TAB 3 - PUSH FOR REMOVAL 4 - APPS CONNECTOR
Fig.6APPSREMOVE/INSTALL(LATE)
(7) If cable is to be separated at APPS, unsnap cable clip from ball socket (Fig. 7). Release cable from plastic housing by pressing on small cable release tab (Fig. 6).
1 - BOTTOM OF BATTERY TRAY 2 - ELECTRICAL CONNECTOR 3 - APPS 4 - SWING-DOWN DOOR 5 - CABLE (TO PEDAL) 6 - CABLE RELEASE TAB
FUEL INJECTION - DIESEL
14 - 82
ACCELERATOR PEDAL POSITION SENSOR (Continued)DR
done (one time) to ensure accelerator pedal position sensor calibration has been learned by ECM. If not done, possible DTC’s may be set.
(12) Use DRB 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.
engine.
(b) Turn key switch ON, but do not crank
(c) Leave key switch ON for a minimum of 10
seconds. This will allow ECM to learn electrical parameters. (8) If necessary, use DRB IIIt Scan Tool to eraseany 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.7APPSCABLE(LATE)
1 - APPS LEVER 2 - BALL SOCKET 3 - SWING-DOWN DOOR 4 - CABLE CLIP 5 - CABLE
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 be
FUEL INJECTION - DIESEL
14 - 83
DR CAMSHAFT POSITION SENSOR (Continued)
The CMP (Fig. 8) provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information pri- marily on engine start-up. Once the engine is run- ning, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running.
Fig.95.9LDIESELCMP
1 - CMP 2 - FUEL INJECTION PUMP (BOTTOM) 3 - ELECTRONIC CONTROL MODULE (ECM) 4 - ECM ELEC. CONNECTOR 5 - CMP ELEC. CONNECTOR 6 - CMP MOUNTING BOLT 7 - BACK OF TIMING GEAR COVER
CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sen- sor mounting tang may result.
(4) Install mounting bolt and tighten. Refer to
Torque Specifications.
(5) Connect electrical connector to sensor.
CRANKSHAFT POSITION SENSOR DESCRIPTION
The Crankshaft Position Sensor (CKP) on the die- sel engine is attached at the front / left side of the engine next to the engine harmonic balancer.
OPERATION
The Crankshaft Position Sensor (CKP) is the pri- mary engine speed indicator for the engine after the engine is running (Fig. 10). The CKP contains a hall effect device. A rotating, notched target wheel (tone- wheel) for the CMP is located on the engine har- monic balancer (Fig. 11). This hall effect device detects notches located on the tonewheel. As the
Fig.85.9LDIESELCMP
1 - CMP 2 - FUEL INJECTION PUMP (BOTTOM) 3 - ELECTRONIC CONTROL MODULE (ECM) 4 - ECM ELEC. CONNECTOR 5 - CMP ELEC. CONNECTOR 6 - CMP MOUNTING BOLT 7 - BACK OF TIMING GEAR COVER
REMOVAL
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 (Fig. 9).
(1) Disconnect electrical connector at CMP sensor
(Fig. 9).
(2) Remove sensor mounting bolt. (3) Carefully twist sensor from timing gear cover. (4) Check condition of sensor o-ring.
INSTALLATION
(1) Clean out machined hole in back of timing gear
cover.
o-ring.
(2) Apply a small amount of engine oil to sensor
(3) Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into posi- tion as damage to o-ring may result.
FUEL INJECTION - DIESEL
14 - 84
CRANKSHAFT POSITION SENSOR (Continued)DR
tonewheel rotates, the notches pass the tip of the CKP.
When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interrup- tion 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 CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts.
The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed.
Fig.11CKPNOTCHEDTONEWHEEL
1 - ENGINE HARMONIC BALANCER 2 - NOTCHED TONEWHEEL 3 - FRONT OF CRANKSHAFT
Fig.125.9LDIESELCKP
1 - ENGINE HARMONIC BALANCER 2 - FRONT OF TIMING GEAR COVER 3 - CKP MOUNTING BOLT 4 - ELEC. CONNECTOR 5 - CKP SENSOR 6 - NOTCHES
(3) Install electrical connector to CKP sensor (Fig.
12).
Fig.105.9LDIESELCKP
1 - ENGINE HARMONIC BALANCER 2 - FRONT OF TIMING GEAR COVER 3 - CKP MOUNTING BOLT 4 - ELEC. CONNECTOR 5 - CKP SENSOR 6 - NOTCHES
REMOVAL
(1) Raise and support vehicle (2) Disconnect electrical connector at CKP sensor
(Fig. 12).
(3) Remove 1 sensor mounting bolt. (4) Remove CKP sensor.
INSTALLATION
(1) Position and install CKP sensor to engine. (2) Install 1 sensor mounting bolt. Refer to Torque
Specifications.
DR
FUEL INJECTION - DIESEL
14 - 85
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
tor (FCA).
(1) Install new o-rings to the Fuel Control Actua-
(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.13FUELCONTROLACTUATOR
1 - ACTUATOR MOUNTING BOLTS 2 - FCA (FUEL CONTROL ACTUATOR) 3 - ACTUATOR ELECTRICAL CONNECTOR
Fig.14FUELINJECTOR-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
FUEL INJECTION - DIESEL
14 - 86
FUEL INJECTOR (Continued)DR
1 - HIGH-PRESSURE CONNECTOR (TO FUEL INJECTOR) 2 - O-RING 3 - CONNECTOR RETAINER
4 - FUEL RAIL 5 - HIGH-PRESSURE FUEL LINES 6 - LOCATING PINS
Fig.15HIGH-PRESSURECONNECTOR
OPERATION
High-pressure fuel is supplied from the injection pump, through a high-pressure fuel line, through a fuel pressure limiting valve, into a fuel rail, through high-pressure lines, through steel connectors and into the solenoid actuated fuel injector. The ECM actuates the solenoid causing the needle valve to rise and fuel flows through the spray holes in the nozzle tip into the combustion chamber.
Each fuel injector is connected to the fuel rail by a high-pressure fuel line with a steel connector. This steel connector is positioned into the cylinder head and sealed with an o-ring. The connectors are sealed to the high-pressure fuel lines with fittings. The fer- rule on the end of the high-pressure fuel line pushes against the steel connector when the fuel line fitting is torqued into the cylinder head. This torquing force provides a sealing pressure between both the fuel line-to-connector and the fuel connector-to-fuel injec- tor. The fitting torque is very critical. If the fit- ting is under torqued, the mating surfaces will not seal and a high-pressure fuel leak will result. If the fitting is over torqued, the connector and injector will deform and also cause a high-pressure fuel leak. This leak will be inside the cylinder head and will not be
visible. The result will be a possible fuel miss-fire and low power.
injector
The fuel injectors use hole type nozzles. High-pres- sure flows into the side of the injector, the ECM acti- vates the solenoid causing the injector needle to lift and fuel to be injected. The clearances in the nozzle bore are extremely small and any sort of dirt or con- taminants will cause the injector to stick. Because of this, it is very important to do a thorough cleaning of any lines before opening up any fuel system compo- nent. Always cover or cap any open fuel connections before a fuel system repair is performed.
Each fuel injector connector tube contains an edge filter that breaks up small contaminants that enter the injector. The edge filter uses the injectors pulsat- ing high-pressure to break up most particles so they are small enough to pass through the injector. The edge filters are not a substitute for proper cleaning and covering of all fuel system compo- nents during repair.
The bottom of each fuel injector is sealed to the cylinder head with a 1.5mm thick copper shim (gas- ket). The correct thickness shim must always be re- installed after removing an injector.
Fuel pressure in the injector circuit decreases after injection. The injector needle valve is immediately
DR FUEL INJECTOR (Continued)
closed and fuel flow into the combustion chamber is stopped. Exhaust gases are prevented from entering the injector nozzle by the needle valve.
REMOVAL
CAUTION: Refer to Cleaning Fuel System Parts.
Six individual, solenoid actuated high-pressure fuel injectors are used (Fig. 14). The injectors are verti- cally mounted into a bored hole in the top of the cyl- inder head. This bored hole is located between the intake/exhaust valves. High-pressure connectors (Fig. 15), mounted into the side of the cylinder head, con- nect each fuel injector to each high-pressure fuel line. (1) Disconnect both negative battery cables from
both batteries. Cover and isolate ends of cables.
(2) Remove breather assembly. (3) Remove valve cover. Refer to Engines for proce-
dures.
(4) Remove necessary high pressure fuel line con- necting necessary fuel injector rail to high pressure connector. Refer to Fuel Line Removal for procedures. (5) A connector retainer (nut) (Fig. 15) is used on each connector tube. Remove this nut(s) by unthread- ing from cylinder head.
(6) Using special high-pressure connector removal tool #9015 (Fig. 16), or (Fig. 17) remove necessary high-pressure connector(s) from cylinder head. Tool #9015 threads onto connector tube. Use tool to pry connector tube(s) from cylinder head.
(7) Remove necessary exhaust rocker arm assem-
bly(s).
injectors (Fig. 18).
(8) Disconnect injector solenoid wire nuts at top of
(9) Remove 2 fuel injector hold-down clamp bolts
at each injector being removed.
(10) USING TOOL #9010:
(a) Special Tool #9010 (Fig. 19) is equipped with 2 clamshell clamps, a sliding retainer sleeve to retain the clamshell clamps, a 2–piece mounting stud, and a pivoting handle. Do not attempt to remove the fuel injector with any other device. Damage to injector will occur.
(b) The rocker housing (Fig. 18) is bolted to the top of cylinder head. The mounting stud from tool #9010 was meant to temporarily replace a rocker housing mounting bolt. Remove the necessary rocker housing mounting bolt. These mounting bolts are located at the center of each of the 3
rocker housing support bridges.(c) Install and tighten 2–piece mounting stud to rocker housing. If removing the #6 fuel injector, separate the 2–piece mounting stud. Install lower half of mounting stud to center of rocker housing bridge. Install upper half of mounting stud to lower half.
FUEL INJECTION - DIESEL
14 - 87
(d) Position tool handle to mounting stud and install handle nut. Leave handle nut loose to allow a pivoting action.
(e) Position lower part of clamshell halves to sides of fuel injector (wider shoulder to bottom). The upper part of clamshell halves should also be positioned into machined shoulder on the handles pivoting head.
(f) Slide the retainer sleeve over pivoting handle
head to lock clamshell halves together. (g) Be sure handle pivot nut is loose. (h) Depress handle downward to remove fuel
injector straight up from cylinder head bore. (11) Remove and discard injector sealing washer. This should be located on tip of injector (Fig. 20) or (Fig. 21).
Fig.16CONNECTORTUBEREMOVAL
1 - CONNECTOR TUBE 2 - TOOL #9015
3 - CYLINDER HEAD (LEFT SIDE)INSTALLATION
(1) Inspect fuel injector.
(a) Look for burrs on injector inlet. (b) Check nozzle holes for hole erosion or plug-
ging.
machine marks.
(c) Inspect end of nozzle for burrs or rough
(d) Look for cracks at nozzle end. (e) Check nozzle color for signs of overheating. Overheating will cause nozzle to turn a dark yellow/ tan or blue (depending on overheating temperature). (f) If any of these conditions occur, replace injector. injector cylinder head bore with special Cummins wire brush tool or equiva- lent (Fig. 22). Blow out bore hole with compressed air.
(2) Thoroughly clean fuel
FUEL INJECTION - DIESEL
14 - 88
FUEL INJECTOR (Continued)DR
Fig.17TOOL#9015ANDCONNECTORTUBE
1 - CONNECTOR TUBE 2 - LOCATING PINS 3 - RUBBER O-RING 4 - TOOL #9015
Fig.19FUELINJECTORREMOVER-#9010
Fig.20FUELINJECTORSEALINGWASHER(SHIM)
LOCATION
1 - FUEL INJECTOR 2 - COPPER SEALING WASHER (SHIM)
certain 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 (.060”)
(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.18FUELINJECTORS
1 - SOLENOID CONNECTIONS 2 - ROCKER HOUSING 3 - FUEL INJECTOR 4 - PASSTHROUGH CONNECTOR
(3) The bottom of fuel injector is sealed to cylinder head bore with a copper sealing washer (shim) of a
DR FUEL INJECTOR (Continued)
Fig.21MEASURINGINJECTORSEALINGWASHER
(SHIM)
1 - SHIM
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
retainer nut. Tighten nut to 50 N·m (37 ft. torque.
connector and its lbs.)
(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 INJECTION - DIESEL
14 - 89
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
lines and fuel
CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system com- ponents. This especially includes the fuel injectors, high-pressure 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.22CLEANINGCYLINDERHEADINJECTOR
BORE-TYPICALBORE
1 - TYPICAL INJECTOR BORE 2 - WIRE BRUSH
FUEL INJECTION - DIESEL
14 - 90
FUEL INJECTOR RAIL (Continued)(8) Remove 3 injector rail mounting bolts (Fig. 23). (9) Remove rail from top of intake manifold.
DR
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).
Fig.23FUELINJECTORRAIL
1 - FUEL RAIL MOUNTING BOLTS (3) 2 - INSULATED CLAMPS 3 - FUEL INJECTOR RAIL
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.
and install new tie wraps.
(4) Reposition wiring harness to intake manifold
(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.
Fig.24IAT/PRESSURESENSORLOCATION-5.9L
DIESEL
1 - CLIPS 2 - FILTER COVER 3 - FILTER MINDER™ 4 - INLET AIR TEMPERATURE/ PRESSURE SENSOR 5 - FILTER HOUSING
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.
DR INLET AIR TEMPERATURE SENSOR/PRESSURE SENSOR (Continued)
FUEL INJECTION - DIESEL
14 - 91
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.25INLET/PRESSURESENSORREMOVAL/
INSTALLATION
1 - INLET/PRESSURE SENSOR 2 - ELEC. CONNECTOR 3 - SENSOR MOUNTING SCREWS (2) 4 - TOP OF AIR FILTER COVER
Fig.26SENSORO-RING
1 - IAT/PRESSURE SENSOR 2 - O-RING
FUEL INJECTION - DIESEL
14 - 92
INTAKE AIR HEATER (Continued)DR
Fig.27INTAKETUBEANDCONNECTINGHOSE
1 - MANIFOLD ABOVE HEATERS 2 - RUBBER CONNECTING HOSE 3 - METAL INTAKE TUBE 4 - CLAMPS (2)
Fig.29AIRHEATERELEMENTS
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
(5) Install engine oil dipstick tube and mounting
(6) Connect rubber connector hose and intake tube
to air intake housing.
(7) Connect both negative battery cables at both
bolt.
batteries.
Fig.28AIRHEATERMANIFOLD
1 - GROUND CABLE 2 - MOUNTING BOLTS (4) 3 - RUBBER COVERS 4 - OIL DIPSTICK TUBE 5 - DIPSTICK MOUNTING BOLT 6 - NUT (GROUND CABLE)
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.DR INTAKE AIR HEATER RELAY (Continued)
FUEL INJECTION - DIESEL
14 - 93
(3) Lift four rubber shields from all 4 cables. (4) Remove four nuts at cable connectors. Note
position of wiring before removing.
(5) Remove relay mounting bracket bolts and
remove relay assembly.
INSTALLATION
(1) Install relay assembly to battery tray. Tighten
mounting bolts to 4.5 N·m (40 in. lbs.) torque.
(2) Connect eight electrical connectors to relays. (3) Connect battery cables to both batteries.
INTAKE AIR TEMPERATURE SENSOR/MAP SENSOR DESCRIPTION
The combination, dual
function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold.
OPERATION
The combination, dual
function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor ele- ment extending into the air stream.
The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicat- ing intake manifold air temperature. The MAP por- tion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure.
REMOVAL
The combination, dual
function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) sensor is installed into the top of the intake manifold (Fig. 31).
(1) Clean area around sensor. (2) Disconnect electrical connector from IAT/MAP
Fig.30INTAKEMANIFOLDAIRHEATERRELAYS 1 - BATTERY 2 - CABLES TO INTAKE HEATERS 3 - RELAY TRIGGER WIRES 4 - INTAKE AIR HEATER RELAYS (2)
Refer to Powertrain Diagnostic Procedures for an electrical operation and complete description of the intake heaters, including pre-heat and post-heat cycles.
REMOVAL
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).
The mounting bracket and both relays are replaced
(1) Disconnect both negative battery cables at both
sensor.
as an assembly.
batteries.
(2) Disconnect four relay trigger wires at both
relays. Note position of wiring before removing.
(3) Remove two T-15 Torx headed screws. (4) Remove sensor from intake manifold. (5) Check condition of sensor o-ring (Fig. 32).
FUEL INJECTION - DIESEL
14 - 94
INTAKE AIR TEMPERATURE SENSOR/MAP SENSOR (Continued)DR
INSTALLATION
(1) Check condition of sensor o-ring. (2) Clean sensor mounting area at intake manifold (3) Position sensor into intake manifold. (4) Install and tighten 2 screws. (5) Connect electrical connector to sensor.
MAP SENSOR DESCRIPTION
A combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is used. Refer to Intake Air Temperature Sensor/MAP Sensor for infor- mation.
THROTTLE CONTROL CABLE REMOVAL
Early Diesel Engine
(1) Disconnect both negative battery cables at both
batteries.
(2) From inside vehicle, hold up accelerator pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Fig. 33). The plas- tic cable retainer snaps into pedal arm.
(3) From inside vehicle, remove cable clip (Fig. 33). (4) Remove cable core wire at pedal arm. (5) Remove cable housing from dash panel and
pull cable into engine compartment.
(6) Remove cable cover (Fig. 34). Cable cover is attached with 2 Phillips screws, 2 plastic retention clips and 2 push tabs (Fig. 34). Remove 2 Phillips screws and carefully pry out 2 retention clips. After clip removal, push rearward on front tab, and upward on lower tab for cover removal.
(7) Using 2 screwdrivers, pry cable connector socket from throttle lever ball (Fig. 35). Be very careful not to bend throttle lever arm.
Fig.31INTAKE/MAPSENSOR
1 - TOP OF INTAKE MANIFOLD 2 - IAT/MAP SENSOR 3 - ELEC. CONNECTOR 4 - MOUNTING BOLTS (2)
Fig.32SENSORO-RING
1 - IAT/MAP SENSOR 2 - O-RING
DR THROTTLE CONTROL CABLE (Continued)
FUEL INJECTION - DIESEL
14 - 95
Fig.33ACCELERATORPEDALMOUNTING
1 - ACCELERATOR CABLE 2 - PLASTIC RETAINER (CLIP) 3 - THROTTLE PEDAL ARM 4 - PEDAL / BRACKET ASSEMBLY 5 - CABLE CLIP
Fig.35SERVOCABLEATTHROTTLELEVER
1 - PINCH (2) TABS 2 - CABLE MOUNTING BRACKET 3 - PINCH TABS (2) 4 - OFF 5 - THROTTLE CABLE 6 - THROTTLE LEVER 7 - THROTTLE LEVER PIN 8 - OFF 9 - CONNECTOR 10 - SPEED CONTROL CABLE
Late Diesel Engine
The Throttle Control Cable on the late diesel engine connects the accelerator pedal to the Acceler- ator Pedal Position Sensor (APPS). A separate
