Dodge Durango (DN). Manual — part 19

(5) Disconnect the idle purge vacuum line from fit-

ting at throttle body. This vacuum line is located on
the front of throttle body next to the MAP sensor
(Fig. 16). Cap the fitting at throttle body after vac-
uum line has been removed.

(6) Connect the DRB scan tool to the 16–way data

link connector. This connector is located under the
instrument panel to the left of the steering column.
Refer to the appropriate Powertrain Diagnostic Pro-
cedures service manual for DRB operation.

(7) Start the engine and allow to warm up.
(8) Using the DRB scan tool, scroll through the

menus as follows: select—Stand Alone DRB III, select
the year 2000 Diagnostics, select—Engine, select—
System Test, select—Minimum Air Flow.

(9) The DRB scan tool will count down to stabilize

the idle rpm and display the minimum air flow idle
rpm. The idle rpm should be between 500 and 900
rpm. If the idle speed is outside of these specifica-
tions, replace the throttle body. Refer to Throttle
Body in the Component Removal/Installation section
of this group.

(10) Disconnect the DRB scan tool from the vehi-

cle.

(11) Remove cap from idle purge fitting at throttle

body and install vacuum line.

(12) Remove orifice tool and connect vacuum line

to PCV valve.

(13) Install air duct to throttle body.

REMOVAL AND INSTALLATION

AUTOMATIC SHUTDOWN (ASD) RELAY

The ASD relay is located in the Power Distribution

Center (PDC) (Fig. 17). Refer to label on PDC cover
for relay location.

REMOVAL

(1) Remove PDC cover.
(2) Remove relay from PDC.
(3) Check condition of relay terminals and PDC

connector terminals for damage or corrosion. Repair
if necessary before installing relay.

(4) Check for pin height (pin height should be the

same for all terminals within the PDC connector).
Repair if necessary before installing relay.

INSTALLATION

(1) Install relay to PDC.
(2) Install cover to PDC.

FUEL PUMP RELAY

The fuel pump relay is located in the Power Distri-

bution Center (PDC) (Fig. 17). Refer to label on PDC
cover for relay location.

REMOVAL

(1) Remove PDC cover.
(2) Remove relay from PDC.
(3) Check condition of relay terminals and PDC

connector terminals for damage or corrosion. Repair
if necessary before installing relay.

(4) Check for pin height (pin height should be the

same for all terminals within the PDC connector).
Repair if necessary before installing relay.

Fig. 16 Idle Purge Line

1 – THROTTLE BODY
2 – PURGE VACUUM LINE

Fig. 17 Power Distribution Center (PDC) Location

1 – POWER DISTRIBUTION CENTER (PDC)

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FUEL SYSTEM

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DIAGNOSIS AND TESTING (Continued)

INSTALLATION

(1) Install relay to PDC.
(2) Install cover to PDC.

OXYGEN SENSOR HEATER RELAYS

The oxygen sensor heater relays are located in the

Power Distribution Center (PDC) (Fig. 17). Refer to
label on PDC cover for relay location.

REMOVAL

(1) Remove PDC cover.
(2) Remove relay from PDC.
(3) Check condition of relay terminals and PDC

connector terminals for damage or corrosion. Repair
if necessary before installing relay.

(4) Check for pin height (pin height should be the

same for all terminals within the PDC connector).
Repair if necessary before installing relay.

INSTALLATION

(1) Install relay to PDC.
(2) Install cover to PDC.

THROTTLE BODY—3.9/5.2/5.9L ENGINES

A (factory adjusted) set screw is used to mechani-

cally limit the position of the throttle body throttle
plate. Never attempt to adjust the engine idle
speed using this screw. All idle speed functions are
controlled by the powertrain control module (PCM).

REMOVAL

(1) Remove the air duct at throttle body.
(2) Disconnect throttle body electrical connectors

at MAP sensor, IAC motor and TPS (Fig. 18).

(3) Remove vacuum line at throttle body.
(4) Remove all control cables from throttle body

(lever) arm. Refer to the Accelerator Pedal and Throt-
tle Cable section of this group for additional informa-
tion.

(5) Remove four throttle body mounting bolts (Fig.

19).

(6) Remove throttle body from intake manifold.
(7) Discard old throttle body-to-intake manifold

gasket.

INSTALLATION

(1) Clean the mating surfaces of the throttle body

and the intake manifold.

(2) Install new throttle body-to-intake manifold

gasket.

(3) Install throttle body to intake manifold.
(4) Install four mounting bolts. Tighten bolts to 23

N·m (200 in. lbs.) torque.

(5) Install control cables.
(6) Install vacuum line to throttle body.
(7) Install electrical connectors.

(8) Install air duct at throttle body.

THROTTLE BODY—4.7L V-8 ENGINE

A (factory adjusted) set screw is used to mechani-

cally limit the position of the throttle body throttle

Fig. 18 Sensor Electrical Connectors—3.9/5.2/5.9L

Engines—Typical

1 – MAP SENSOR
2 – IDLE AIR CONTROL MOTOR
3 – THROTTLE POSITION SENSOR

Fig. 19 Throttle Body Mounting Bolts—3.9/5.2/5.9L

Engines—Typical

1 – THROTTLE BODY MOUNTING BOLTS (4)
2 – THROTTLE BODY

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FUEL SYSTEM

14 - 45

REMOVAL AND INSTALLATION (Continued)

plate. Never attempt to adjust the engine idle
speed using this screw. All idle speed functions are
controlled by the Powertrain Control Module (PCM).

REMOVAL

(1) Remove the air duct and air resonator box at

throttle body.

(2) Disconnect throttle body electrical connectors

at IAC motor and TPS (Fig. 20).

(3) Remove vacuum line at throttle body.
(4) Remove all control cables from throttle body

(lever) arm. Refer to Accelerator Pedal and Throttle
Cable.

(5) Remove three throttle body mounting bolts

(Fig. 20).

(6) Remove throttle body from intake manifold.

INSTALLATION

(1) Clean throttle body-to-intake manifold o-ring.
(2) Clean mating surfaces of throttle body and

intake manifold.

(3) Install throttle body to intake manifold by posi-

tioning throttle body to manifold alignment pins.

(4) Install three mounting bolts. Tighten bolts to

12 N·m (105 in. lbs.) torque.

(5) Install control cables.
(6) Install vacuum line to throttle body.
(7) Install electrical connectors.

(8) Install air duct/air box at throttle body.

THROTTLE POSITION SENSOR (TPS)—3.9/5.2/
5.9L ENGINES

REMOVAL

The TPS is located on side of throttle body.
(1) Remove air duct at throttle body.
(2) Disconnect TPS electrical connector.
(3) Remove two TPS mounting bolts (Fig. 21).

(4) Remove TPS from throttle body.

INSTALLATION

The throttle shaft end of the throttle body slides

into a socket in the TPS (Fig. 22). The TPS must be
installed so that it can be rotated a few degrees. If
the sensor will not rotate, install the sensor with the
throttle shaft on the other side of the socket tangs.
The TPS will be under slight tension when rotated.

(1) Install the TPS and two retaining bolts.
(2) Tighten bolts to 7 N·m (60 in. lbs.) torque.
(3) Manually operate the throttle control lever by

hand to check for any binding of the TPS.

(4) Connect TPS electrical connector to TPS.
(5) Install air duct at throttle body.

THROTTLE POSITION SENSOR (TPS)—4.7L
V-8 ENGINE

REMOVAL

The TPS is located on the throttle body.
(1) Remove air duct and air resonator box at throt-

tle body.

(2) Disconnect TPS electrical connector (Fig. 20).
(3) Remove two TPS mounting bolts (screws) (Fig.

23).

Fig. 20 Throttle Body, Sensors and Electrical

Connectors—4.7L V-8 Engine

1 – MOUNTING BOLTS (3)
2 – THROTTLE BODY
3 – IAT SENSOR CONNECTOR
4 – IAC MOTOR CONNECTOR
5 – TPS CONNECTOR

Fig. 21 TPS Mounting Bolts—3.9/5.2/5.9L Engines

1 – THROTTLE POSITION SENSOR
2 – MOUNTING SCREWS

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FUEL SYSTEM

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REMOVAL AND INSTALLATION (Continued)

(4) Remove TPS from throttle body.

INSTALLATION

The throttle shaft end of throttle body slides into a

socket in TPS (Fig. 24). The TPS must be installed so
that it can be rotated a few degrees. If sensor will
not rotate, install sensor with throttle shaft on other
side of socket tangs. The TPS will be under slight
tension when rotated.

(1) Install TPS and two retaining bolts.
(2) Tighten bolts to 7 N·m (60 in. lbs.) torque.
(3) Manually operate throttle control lever by hand

to check for any binding of TPS.

(4) Connect TPS electrical connector to TPS.
(5) Install air duct/air box to throttle body.

IDLE AIR CONTROL (IAC) MOTOR—3.9/5.2/
5.9L ENGINES

The IAC motor is located on the back of the throt-

tle body (Fig. 25).

REMOVAL

(1) Remove air duct at throttle body.
(2) Disconnect electrical connector from IAC motor.
(3) Remove two mounting bolts (screws) (Fig. 25).
(4) Remove IAC motor from throttle body.

INSTALLATION

(1) Install IAC motor to throttle body.

Fig. 22 Installation—3.9/5.2/5.9L Engines—Typical

1 – THROTTLE BODY
2 – THROTTLE POSITION SENSOR
3 – THROTTLE SHAFT
4 – SOCKET LOCATING TANGS

Fig. 23 TPS Mounting Bolts—4.7L V–8 Engine

1 – THROTTLE BODY
2 – TPS
3 – IAC MOTOR
4 – IAT SENSOR
5 – MOUNTING SCREWS

Fig. 24 TPS Installation—4.7L V–8 Engine

1 – THROTTLE BODY
2 – LOCATING TANGS
3 – THROTTLE POSITION SENSOR
4 – SOCKET
5 – THROTTLE SHAFT

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FUEL SYSTEM

14 - 47

REMOVAL AND INSTALLATION (Continued)