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INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 93
INTAKE 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
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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
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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
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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
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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
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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
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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
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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 mechanical cable is not routed to the throttle body.
CAUTION: Be careful not to damage or kink cable core wire (within cable sheathing) while servicing accelerator pedal, cables or APPS.
Fig.34CABLE/LEVER/THROTTLELINKAGECOVER 1 - CABLE/LEVER/LINKAGE COVER 2 - PUSH UP LOWER TAB 3 - SCREWS/CLIPS (2) 4 - TAB PUSH HERE
(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. 36). The plas- tic cable retainer snaps into pedal arm.
(3) Remove cable core wire at pedal arm. (4) Remove APPS. Refer to (Diesel) Accelerator Pedal Position Sensor (APPS) Removal / Installation. (5) From inside vehicle, remove cable clip (Fig. 36). (6) Remove cable housing from dash panel and
pull cable into engine compartment.
(7) Remove cable housing at APPS bracket by pressing on release tab with a small screwdriver. To prevent cable housing breakage, press on tab only enough to release cable from APPS bracket.
FUEL INJECTION - DIESEL
14 - 96
THROTTLE CONTROL CABLE (Continued)DR
(3) Install remaining cable housing end into and through dash panel opening (snaps into position). The two plastic pinch tabs should lock cable to dash panel.
(4) From inside vehicle, hold up accelerator pedal. Install throttle cable core wire and plastic cable retainer into and through upper end of pedal arm (the plastic retainer is snapped into pedal arm). When installing plastic retainer to accelerator pedal arm, note index tab on pedal arm (Fig. 33). Align index slot on plastic cable retainer to this index tab. (5) Connect negative battery cables to both batter-
ies.
(6) Before starting engine, operate accelerator
pedal to check for any binding.
(7) Install cable/lever cover.
Fig.36ACCELERATORPEDALMOUNTING
1 - ACCELERATOR CABLE 2 - PLASTIC RETAINER (CLIP) 3 - THROTTLE PEDAL ARM 4 - PEDAL / BRACKET ASSEMBLY 5 - CABLE CLIP
INSTALLATION
Early Diesel Engine
(1) Install cable through mounting hole on cable mounting bracket (Fig. 35). Cable snaps into bracket. Be sure 2 pinch tabs are secure.
(2) Using large pliers, connect cable end socket to
throttle lever ball (snaps on).
Late Diesel Engine
(1) Attach cable to Accelerator Pedal Position Sen- sor (APPS). Refer to APPS (Diesel) Removal / Instal- lation.
(2) Push cable housing into rubber grommet and
through opening in dash panel.
(3) From inside vehicle, install clip holding cable
to dashpanel (Fig. 36).
(4) From inside vehicle, slide throttle cable core
wire into opening in top of pedal arm.
(5) Push cable retainer (clip) into pedal arm open-
ing until it snaps in place.
(6) Before starting engine, operate accelerator
pedal to check for any binding.
(7) If necessary, use DRB IIIt Scan Tool to erase from
any APPS Diagnostic Trouble Codes (DTC’s) PCM.
DR
STEERING
19 - 1
STEERING
TABLE OF CONTENTS
page
page
STEERING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - POWER
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - POWER
STEERING FLOW AND PRESSURE . . . . . . . . 4
SPECIAL TOOLS
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STEERING DESCRIPTION
CAUTION: MOPART ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill.
Power steering systems consist of: † Steering column † Rack and pinion steering gear † Belt driven hydraulic steering pump † Pump pressure and return hoses † Oil Cooler OPERATION
The steering column shaft is attached to the gear pinion. The rotation of the pinion moves the gear rack from side-to-side. This lateral action of the rack pushes and pulls the tie rods to change the direction of the front wheels (Fig. 1).
Power assist is provided by an engine mounted hydraulic pump which supplies hydraulic fluid pres- sure to the steering gear.
COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
GEAR - INDEPENDENT FRONT SUSPENSION . . 16
GEAR - LINK/COIL . . . . . . . . . . . . . . . . . . . . . . . 19
LINKAGE - INDEPENDENT FRONTSUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
. . . . . . . . . . . . . . . . . . . . 33
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38LINKAGE - LINK/COIL PUMP
Fig.1STEERINGCOMPONENTS
1 - POWER STEERING PUMP ASSEMBLY 2 - RESERVOIR 3 - HOSES 4 - TIE ROD ENDS 5 - MOUNTING BOLTS 6 - RACK & PINION
STEERING
19 - 2
STEERING (Continued) DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - POWER STEERING SYSTEM
DR
There is some noise in all power steering systems. One of the most common is a hissing sound evident at a standstill parking. Or when the steering wheel is at the end of it’s travel. Hiss is a high frequency noise similar to that of a water tap being closed slowly. The noise is present in all valves that have a high velocity fluid passing through an orifice. There is no relationship between this noise and steering performance.
STEERING NOISE
CONDITION
POSSIBLE CAUSES
CORRECTION
OBJECTIONAL HISS OR WHISTLE
1. Steering intermediate shaft to dash panel seal.
1. Check and repair seal at dash panel.
RATTLE OR CLUNK
1. Gear mounting bolts loose.
1. Tighten bolts to specification.
2. Noisy valve in power steering gear.
2. Replace steering gear.
2. Loose or damaged suspension components. 3. Internal gear noise. 4. Pressure hose in contact with other components. 5. Loose or damaged intermediate shaft or column.
2. Inspect and repair suspension.
3. Replace steering gear. 4. Reposition hose.
5. Inspect and repair or replace.
CHIRP OR SQUEAL
1. Loose belt.
WHINE OR GROWL
1. Low fluid level.
2. Pressure hose in contact with other components. 3. Internal pump noise. 4. Air in fluid
SUCKING AIR SOUND
1. Loose return line clamp.
2. O-ring missing or damaged on hose fitting. 3. Low fluid level. 4. Air leak between pump and reservoir. 5. Reservoir cap not installed correctly.
1. Adjust or replace.
1. Fill to proper level.
2. Reposition hose.
3. Replace pump. 4. Check for lekas, Evacuate air from P/S system.
1. Replace clamp.
2. Replace o-ring.
3. Fill to proper level. 4. Repair as necessary. 5. Install reservoir cap correctly.
SCRUBBING OR KNOCKING
1. Wrong tire size.
1. Verify tire size.
DR STEERING (Continued)
STEERING
19 - 3
BINDING AND STICKING
CONDITION
POSSIBLE CAUSE
CORRECTION
DIFFICULT TO TURN WHEEL
STICKS OR BINDS
1. Low fluid level. 2. Tire pressure. 3. Steering components (ball joints/tie rod ends). 4. Loose belt. 5. Low pump pressure.
6. Column shaft coupler binding. 7. Steering gear worn. 8. Pump seized / Stuck valve
1. Fill to proper level. 2. Adjust tire pressure. 3 Inspect and repair as necessary.
4. Adjust or replace. 5. Pressure test and replace if necessary. 6. Replace coupler. 7. Replace gear. 8. Replace pump.
INSUFFICIENT ASST. OR POOR RETURN TO CENTER
CONDITION
POSSIBLE CAUSE
CORRECTION
HARD TURNING OR MOMENTARY INCREASE IN TURNING EFFORT
STEERING WHEEL DOES NOT WANT TO RETURN TO CENTER POSITION
1. Tire pressure.
1. Adjust tire pressure.
2. Low fluid level. 3. Loose belt. 4. Low pump pressure.
5. Internal gear leak.
1. Tire pressure. 2. Wheel alignment. 3. Lack of lubrication.
4. High friction in steering gear.
2. Fill to proper level. 3. Adjust or replace. 4. Pressure test and repair as necessary. 5. Replace gear.
1. Adjust tire pressure. 2. Align front end. 3. Inspect and lubricate suspension compnents. 4. Replace gear.
LOOSE STEERING AND VEHICLE LEAD
CONDITION
POSSIBLE CAUSE
CORRECTION
EXCESSIVE PLAY IN STEERING WHEEL
1. Worn or loose suspension or steering components.
1. Inspect and repair as necessary.
2. Worn or loose wheel bearings.
3. Steering gear mounting.
4. Gear out of adjustment. 5. Worn or loose steering coupler.
VEHICLE PULLS OR LEADS TO ONE SIDE.
1. Tire Pressure. 2. Radial tire lead. 3. Brakes dragging. 4. Wheel alignment.
2. Inspect and repair or adjust bearings. 3. Tighten gear mounting bolts to specification. 4. Replace gear. 5. Inspect and replace as necessary.
1. Adjust tire pressure. 2. Rotate tires. 3. Repair as necessary. 4. Align front end.
STEERING
19 - 4
STEERING (Continued) DIAGNOSIS AND TESTING - POWER STEERING FLOW AND PRESSUREThe following procedure is used to test the opera- tion of the power steering system on the vehicle. This test will provide the gallons per minute (GPM) or flow rate of the power steering pump along with the maximum relief pressure. Perform test any time a power steering system problem is present. This test will determine if the power steering pump or power steering gear is not functioning properly. The follow- ing pressure and flow test is performed using Power Steering Analyzer Tool kit 6815 and (Fig. 2) Adapter Kit 6893.
Fig.2AnalyzerWithTubeandAdapter
1 - TUBE 2 - ADAPTER FITTINGS 3 - ANALYZER 4 - GAUGE HOSE
FLOW AND PRESSURE TEST
(1) Check the power steering belt to ensure it is in
good condition and adjusted properly.
(2) Connect pressure gauge hose from the Power
Steering Analyzer to adapter 6826.
(3) Connect tube 6825A to Power Steering Ana-
lyzer test valve end.
power steering pump.
(4) Disconnect the high pressure hose from the
(5) Connect the tube 6825A to the pump fitting. (6) Connect
the power steering hose from the
steering gear to the adapter 6826.
(7) Open the test valve completely. (8) Start engine and let idle long enough to circu- late power steering fluid through flow/pressure test gauge and to get air out of the fluid. Then shut off engine.
DR
(9) Check fluid level, add fluid as necessary. Start
engine again and let idle.
(10) Gauge should read below 862 kPa (125 psi), if above, inspect the hoses for restrictions and repair as necessary. The initial pressure reading should be in the range of 345-552 kPa (50-80 psi).
(11) Increase the engine speed to 1500 RPM and read the flow meter. If the flow rate (GPM) is below specification, (refer to pump specification chart for GPM) the pump should be replaced.
CAUTION: The following test procedure involves testing maximum pump pressure output and flow control valve operation. Do not leave valve closed for more than three seconds as the pump could be damaged.
(12) Close valve fully three times and record high- est pressure indicated each time. All three read- ings must be above specifications and within 345 kPa (50 psi) of each other. † Pressures above specifications but not within † Pressures within 345 kPa (50 psi) of each other
345 kPa (50 psi) of each other, replace pump.
but below specifications, replace pump.
(13) Open the test valve and turn the steering wheel to the extreme left and right positions three times against the stops. Record the highest pressure reading at each position. Compare readings to the pump specifications chart. If pressures readings are not within 50 psi of each other, the gear is leaking internally and must be replaced.
CAUTION: Do not force the pump to operate against the stops for more than 2 to 3 seconds at a time because, pump damage will result.
PUMP SPECIFICATION
ENGINE
RELIEF
PRESSURE ±
FLOW RATE (GPM) AT 1500
1500 series
2500 & 3500
series
65
11032 kPa
(1615 ± 65 psi)
12400 kPa
(1800 ± 50 psi)
RPM
3.1 - 3.5
3.5 - 4.0
DR STEERING (Continued) SPECIAL TOOLS
STEERING
STEERING
19 - 5
ADAPTER,POWERSTEERINGFLOW/PRESSURE-
6825A
PULLER-8677
ADAPTERS,POWERSTEERINGFLOW/PRESSURE
TESTER-6893
ANALYZERSET,POWERSTEERINGFLOW/
PRESSURE6815
19 - 6
COLUMN
COLUMN
TABLE OF CONTENTS
page
DR
page
COLUMN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING - STEERINGCOLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9IGNITION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - IGNITIONSWITCH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11KEY-IN IGNITION SWITCH
DESCRIPTION DIAGNOSIS AND TESTING - IGNITION
. . . . . . . . . . . . . . . . . . . . . . . . . 11
SWITCH AND KEY LOCK CYLINDER . . . . . . . 11
KEY CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
COLUMN DESCRIPTION
NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative meth- ods of locking the steering wheel for service will have to be used.
The tilt and standard column (Fig. 1) has been designed to be serviced as an assembly; less wiring, switches, shrouds, steering wheel, etc. Most steering column components can be serviced without remov- ing the steering column from the vehicle.
To service the steering wheel, switches or airbag, refer to Restraints and follow all WARNINGS and CAUTIONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL THE AIRBAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DIS- CHARGE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
GEAR SHIFT LEVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12UPPER STEERING COUPLING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14LOWER STEERING COUPLING
REMOVAL
REMOVAL - ALL LD & HD EXCEPT 4X4 HD REMOVAL - 4X4 HD
. 14
. . . . . . . . . . . . . . . . . . . 14INSTALLATION
INSTALLATION - ALL LD & HD EXCEPT 4X4
HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION - 4X4 HD . . . . . . . . . . . . . . . . 15STEERING WHEEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15POSSIBLE PERSONAL INJURY. THE FASTENERS, SCREWS, AND BOLTS, ORIGINALLY USED FOR THE AIRBAG COMPONENTS, HAVE SPECIAL COAT- INGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANYTIME A NEW FASTENER IS NEEDED, REPLACE WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR FASTENERS LISTED IN THE PARTS BOOKS.
CAUTION: Do not hammer on steering column shaft. This may cause damage to the shaft or bear- ing.
CAUTION: Do not attempt to remove the pivot bolts to disassemble the tilting mechanism. Do not remove shaft lock plate or plate retainer. This will damage the column.
CAUTION: Do not attempt to remove or modify the park lock slider or link.
NOTE: When servicing the steering wheel after removing the old bolt a new bolt must be used when installing.
DR COLUMN (Continued)
NOTE: When servicing the coupler a new bolt must be used when installing.
Fig.1STEERINGCOLUMN
1 - LOCK CYLINDER 2 - GEAR SHIFT LEVER 3 - MOUNTING HOLES 4 - STEERING COLUMN 5 - TILT LEVER
DIAGNOSIS AND TESTING - STEERING COLUMN
If the vehicle is involved in a front end collision/the air bag has deployed the column must be inspected. This inspection will determine if the Column has col- lapsed. Inspect the column mounting capsules visu- ally and manually push and pull them to check for separation or fractures. If capsules are fractured or have moved the column MUST be replaced.
REMOVAL
WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DIS- ARMED. REFER TO ELECTRICAL RESTRAINT SYS- TEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY.
CAUTION: All fasteners must be torqued to specifi- cation to ensure proper operation of the steering column.
COLUMN
19 - 7
(1) Position the front wheels straight ahead. (2) Disconnect the negative (ground) cable from
(3) Remove the two switches from the steering
the battery.
wheel.
(4) Remove the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(5) Remove the steering wheel with special tool
CJ98–1 or an appropriate steering wheel puller.
CAUTION: Ensure the puller bolts are fully engaged into the steering wheel and not into the clock- spring, before attempting to remove the wheel. Fail- ure to do so may damage the steering wheel/ clockspring.
(6) Remove the steering column opening cover (Refer to 23 - BODY/INSTRUMENT PANEL/STEER- ING COLUMN OPENING COVER - REMOVAL).
(7) Remove the tilt lever. (8) Remove the column shrouds (Fig. 2).
Fig.2UPPER&LOWERSHROUDS
1 - UPPER SHROUD 2 - LOWER SHROUD
(9) Remove the clock spring, (Refer to 8 - ELEC- TRICAL/RESTRAINTS/CLOCKSPRING - REMOV- AL).
(10) Disconnect the wiring harness to the column. (11) Remove the shift cable from the column shift to 21 - TRANSMISSION/ lever actuator TRANSAXLE/AUTOMATIC - 32RH/GEAR SHIFT CABLE - REMOVAL). (Fig. 3).
(Refer
COLUMN
19 - 8
COLUMN (Continued)DR
Fig.3SHIFTCABLECONNECTOR
Fig.5UPPERSTEERINGCOUPLER
1 - Shift lever 2 - Cable Connection 3 - Overdrive Electrical Wiring 4 - Mounting Screws
(12) Release the shift cable from the column
bracket and remove it from the bracket.
(13) Remove the SKIM module in order to discon-
nect the electrical connector.
(14) Remove the upper steering shaft coupler bolt
and slide the shaft down (Fig. 4) & (Fig. 5)
1 - STEERING COUPLER 2 - PINCH BOLT HOLE
(15) Remove the brake light switch and discard (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - REMOVAL).
(16) Remove the four steering column mounting
nuts (Fig. 6).
Fig.4COUPLERSHAFT
1 - MOUNTING HOLES 2 - COUPLER BOLT HOLE
Fig.6MOUNTINGHOLES
1 - MOUNTING HOLES
(17) Remove the steering column assembly from
the vehicle. (Fig. 7)
DR COLUMN (Continued)
COLUMN
19 - 9
(7) Install the shifter cable. (Refer to 21 - TRANS- MISSION/TRANSAXLE/AUTOMATIC - 32RH/GEAR SHIFT CABLE - INSTALLATION)
(8) Connect the wiring harness to the column. (9) Install the SKIM module. (10) Install the clockspring(Refer to 8 - ELECTRI-
CAL/RESTRAINTS/CLOCKSPRING - REMOVAL).
(11) Install the shrouds. (12) Install
the steering column opening cover (Refer to 23 - BODY/INSTRUMENT PANEL/STEER- ING COLUMN OPENING COVER - INSTALLA- TION).
(13) Align the spline on the wheel hub to shaft. (14) Then install the steering wheel and install a
new bolt. Tighten the bolt to 61 N·m (45 ft. lbs.).
(15) Install the airbag (Refer to 8 - ELECTRICAL/ RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(16) Install the two steering wheel switches. (17) Install the tilt lever handle. (18) Install the negative battery terminal. (19) Test the operation of the horn, Electronic PRNDL Indicator, lights and any other functions that are steering column operated.
IGNITION SWITCH DESCRIPTION
The ignition switch is located on the steering col- umn. It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch.
OPERATION
Vehicles equipped with an automatic trans- mission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed.
DIAGNOSIS AND TESTING - IGNITION SWITCH
TEST AND REPAIR
If the key removal effort is excessive on a vehicle with a automatic transmission first adjust the shift linkage, (Refer to 21 - TRANSMISSION/TRANS- AXLE/AUTOMATIC - 46RE/GEAR SHIFT CABLE - ADJUSTMENTS).
If the ignition switch effort is excessive remove the ignition key cylinder from the steering column. (Refer to 19 - STEERING/COLUMN/LOCK CYLINDER HOUSING - REMOVAL). Check the turning effort of the key cylinder. If the ignition key cylinder effort is excessive replace the key cylinder.
Fig.7STEERINGCOLUMN
1 - Steering Wheel 2 - Key Cylinder 3 - Gear Shift Lever 4 - Steering Column 5 - Tilt Lever Cable
INSTALLATION
WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DIS- ARMED. REFER TO ELECTRICAL RESTRAINT SYS- TEM FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY.
CAUTION: All fasteners must be torqued to specifi- cation to ensure proper operation of the steering column.
(1) Position the steering column on the dash panel
support and loosely install the mounting nuts.
(2) Firmly slide the steering column upward against the studs in dash panel and hand tighten the nuts.
(3) Install the steering shaft coupler on the steer-
ing shaft and loosely install a new bolt.
(4) Center steering column in dash opening and
tighten mounting nuts to 28 N·m (250 in. lbs.).
NOTE: Torque the upper left nut first then the lower right nut. Then torque the lower left nut then the upper right nut.
NOTE: A new bolt must be used for reinstallation.
(5) Tighten the coupler bolt to 57 N·m (42 ft. lbs.). (6) Install a new brake light switch (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ BRAKE LAMP SWITCH - REMOVAL).
DR
THEY MUST NEVER BE AIRBAG SYSTEM. REPLACED WITH ANY SUBSTITUTES. ANYTIME A NEW FASTENER IS NEEDED, REPLACE WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR FASTENERS LISTED IN THE PARTS BOOKS.
CAUTION: Do not hammer on steering column shaft. This may cause damage to the shaft or bear- ing.
CAUTION: Do not attempt to remove the pivot bolts to disassemble the tilting mechanism.
The ignition key must be in the key cylinder for cylinder removal. The key cylinder must be removed first before removing ignition switch.
(1) Remove the negative (ground) cable from the
battery.
(2) Disable the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(3) Remove the lower and upper shrouds. (4) Remove key cylinder. (Refer to 19 - STEER- ING/COLUMN/LOCK CYLINDER HOUSING - REMOVAL).
(5) Disconnect the lower clockspring connectors. (6) Remove the wire retainer from the tilt lever
bracket.
(7) Remove the tilt lever mounting screws to gain access to the ignition switch mounting screws. (Fig. 9)
COLUMN
19 - 10
IGNITION SWITCH (Continued) REMOVALSERVICE PRECAUTIONS
NOTE: The steering column on vehicles equipped with an automatic transmission is not equipped with an internal locking shaft with the ignition cyl- inder. Alternative methods of locking the steering wheel for service will have to be used.
The tilt and standard column (Fig. 8) have been
