ABS DODGE RAM 2002 Service Repair Manual

MANIFOLD ABSOLUTE PRESSURE SENSOR (8.0L)-3WAY
CAV CIRCUIT FUNCTION
1 K6 20VT/WT 5V SUPPLY
2 K4 20BK/LB SENSOR GROUND
3 K1 18DG/RD MAP SENSOR SIGNAL
MANIFOLD ABSOLUTE PRESSURE SENSOR (DIESEL)-3WAY
CAV CIRCUIT FUNCTION
A K7 18OR 5V SUPPLY
B K104 18BK/LB SENSOR GROUND
C G12 18GY/RD MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL
MULTI-FUNCTION SWITCH - 24 WAY
CAV CIRCUIT FUNCTION
1 V9 16WT/DB WIPER SWITCH MODE SIGNAL
2 V8 16VT WIPER SWITCH MODE SENSE
3 V10 16BR WASHER SWITCH SENSE
4 V6 16DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
5 V4 16RD/YL WIPER SWITCH HIGH SPEED OUTPUT
6 V3 16BR/WT LOW SPEED WIPER SWITCH OUTPUT
7 V49 16RD/BK DRIVER LOW SPEED WIPER MOTOR DRIVER
8 V49 16RD/BK DRIVER LOW SPEED WIPER MOTOR DRIVER
9 V3 16BR/WT LOW SPEED WIPER SWITCH OUTPUT
10 - -
11 L60 18TN RIGHT TURN SIGNAL
12 L62 16BR/RD RIGHT TURN SIGNAL
13 L19 16PK HAZARD FLASHER SIGNAL
14 L50 16WT/TN BRAKE LAMP SWITCH OUTPUT
15 L63 16DG/RD LEFT TURN SIGNAL
16 L61 18LG LEFT TURN SIGNAL
17 L6 16RD/GY FLASHER OUTPUT
18 L4 18VT/WT DIMMER SWITCH LOW BEAM OUTPUT
19 L2 18LG HEADLAMP SWITCH OUTPUT
20 L3 14RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
21 Z3 16BK/OR GROUND
22 - -
23 - -
24 - -
8W - 80 - 62 8W-80 CONNECTOR PIN-OUTSBR/BE

RADIO C1 - GRAY 7 WAY
CAV CIRCUIT FUNCTION
1- -
2 X55 18BR/RD LEFT FRONT DOOR SPEAKER (-)
3 X56 18DB/RD RIGHT FRONT DOOR SPEAKER (-)
4 E17 18YL/BK DAY BRIGHTNESS SENSE
5 E2 22OR PANEL LAMPS FEED
6 X12 16RD/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
7 M1 22PK FUSED B(+)
RADIO C2 - BLACK 7 WAY
CAV CIRCUIT FUNCTION
1 X16 22LG ANTENNA RELAY OUTPUT
2 X51 18BR/YL LEFT REAR SPEAKER (+)
3 X52 18DB/WT RIGHT REAR SPEAKER (+)
4 X53 18DG LEFT FRONT DOOR SPEAKER (+)
5 X54 18VT RIGHT FRONT DOOR SPEAKER (+)
6 X57 18BR/LB LEFT REAR SPEAKER (-)
7 X58 18DB/OR RIGHT REAR SPEAKER (-)
RADIO C3-2WAY
CAV CIRCUIT FUNCTION
1 D1 20VT/BR CCD BUS (+)
2 D2 20WT/BK CCD BUS (-)
RADIO CHOKE RELAY - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 X60 16DG/RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
2 X13 16BK/RD RADIO CHOKE RELAY OUTPUT
3 X16 22LG ANTENNA RELAY OUTPUT
4 Z9 16BK/VT GROUND
REAR WHEEL SPEED SENSOR (ABS)-2WAY
CAV CIRCUIT FUNCTION
1 B114 20WT/VT REAR WHEEL SPEED SENSOR (-)
2 B113 20RD/VT REAR WHEEL SPEED SENSOR (+)
8W - 80 - 74 8W-80 CONNECTOR PIN-OUTSBR/BE

RIGHT FRONT WHEEL SPEED SENSOR (ABS) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 B6 20WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
2 B7 20WT RIGHT FRONT WHEEL SPEED SENSOR (+)
RIGHT HEADLAMP - BLACK 3 WAY
CAV CIRCUIT FUNCTION
A L45 18PK/RD FUSED B(+)
B- -
C L33 18LG/BR HIGH BEAM HEADLAMP DRIVER
RIGHT LICENSE LAMP - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 L7 18BK/YL PARK LAMP RELAY OUTPUT
2 Z13 18BK GROUND
RIGHT OUTBOARD CLEARANCE LAMP-2WAY
CAV CIRCUIT FUNCTION
1 L7 18BK/YL HEADLAMP SWITCH OUTPUT
2 Z4 18BK GROUND
RIGHT OUTBOARD HEADLAMP-3WAY
CAV CIRCUIT FUNCTION
C L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
B L44 18VT/RD (QUAD HEADLAMP) FUSED B(+)
B L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT
A L44 18VT/RD FUSED B(+)
A L4 16VT/WT (QUAD HEADLAMP) DIMMER SWITCH LOW BEAM OUTPUT
8W - 80 - 76 8W-80 CONNECTOR PIN-OUTSBR/BE

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Clockspring C1 Steering Column 32
Clockspring C2 Steering Column 32
Clockspring C3 Steering Column 32
Clutch Pedal Position Switch
(M/T)BK Top of Clutch Pedal 35
Controller Anti-Lock Brake C1 BK Left Fender Side Shield 18
Controller Anti-Lock Brake C2
(ABS)BK Left Fender Side Shield 18
Crankshaft Position Sensor
(V8)BK Rear of Engine Block 5
Crankshaft Position Sensor
(V10GY Right Side of Engine Block 8
Cummins Bus (-) Left Front of Engine 13
Cup Holder Lamp BK Center of Instrument Panel 30, 34
Data Link Connector BK Left Bottom of Instrument Panel 30, 32
Day/Night Mirror BK Day/Night Mirror N/S
Daytime Running Lamp
ModuleBK Left Fender Side Shield 18
Dome Lamp BK Rear of Cab 23
Driver Airbag YL Steering Wheel N/S
Driver Cylinder Lock Switch BK In Door 24
Driver Door Ajar Switch NAT Door Jamb N/S
Driver Door Lock Motor BK In Door 24
Driver Door Window/Lock
SwitchBL In Door 24
Driver Heated Seat Cushion BL Under Seat N/S
Driver Heated Seat Switch RD Center of Instrument Panel N/S
Driver Lumbar Motor Under Seat N/S
Driver Power Seat Front
Vertical MotorBK Under Seat N/S
Driver Power Seat Horizontal
MotorBK Under Seat N/S
Driver Power Seat Rear
Vertical MotorBK Under Seat N/S
Driver Power Seat Switch At Seat N/S
Driver Power Window Motor In Door 24
EVAP/Purge Solenoid BK Right Fender Side Shield 22
Electric Brake Provision Bottom Left of Instrument Panel N/S
Engine Control Module
(Diesel)Left Side Engine 15
Engine Coolant Temperature
Sensor (Diesel)BK Left Front of Cylinder Head (Diesel) 13
Engine Coolant Temperature
Sensor (Gas)BK On Thermostat Housing 5, 8
BR/BE8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Joint Connector No. 5 NAT Left Side of Instrument Panel 32
Joint Connector No. 6 NAT Left Side of Instrument Pane 32
Joint Connector No. 7 NAT Left Side of Instrument Pane 32
Joint Connector No. 8 NAT Center of Instrument Panel 30
Junction Block C1 BL Left Cowl 35
Junction Block C2 NAT Left Cowl 35
Junction Block C3 Left Cowl 25
Junction Block C4 BR Left Cowl 33
Junction Block C5 GN Left Cowl 33
Junction Block C6 BK Left Cowl 33
Junction Block C7 LTGY Left Cowl 33
Junction Block C8 OR Left Cowl 33
Junction Block C9 NAT Left Cowl N/S
Leak Detection Pump (Gas) BK Right Fender Side Shield 22
Left Back-Up Lamp GY Rear of Lamp N/S
Left Fog Lamp WT Rear of Fog Lamp N/S
Left Front Door Speaker
(Premium)BK In Door 24
Left Front Door Speaker
(Standard)BK In Door 24
Left Front Fender Lamp BK On Fender N/S
Left Front Wheel Speed
Sensor (ABS)BK Left Fender Side Shield 18
Left Headlamp BL At Headlamp N/S
Left License Lamp BK At Rear Bumper N/S
Left Outboard Clearance
LampBK Behind Front of Headliner 25
Left Outboard Headlamp BL At Headlamp N/S
Left Outboard Identification
LampBK Behind Front of Headliner 25
Left Park/Turn Signal Lamp BK At Lamp N/S
Left Power Mirror BK In Door 24
Left Rear Fender Lamp BK On Fender N/S
Left Rear Speaker (Premium) BK At B Pillar 23
Left Rear Speaker (Standard) At B Pillar 23
Left Rear Door Speaker In Door 23
Left Remote Radio Switch Steering Wheel N/S
Left Speed Control Switch Steering Wheel N/S
Left Tail/Stop Turn Signal
LampBK At Rear Bumper 27
Left Tweeter (Premium) Left A Pillar N/S
Left Visor/Vanity Lamp BK Left A-Pillar 25, 26
License Lamps BK Rear Bumper 27
BR/BE8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Low Note Horn BK Front Bumper Right Support 22
Manifold Absolute Pressure
Sensor (V8)BK On Throttle Body 7
Manifold Absolute Pressure
Sensor (V10)BK Top of Intake Manifold 12
Manifold Air Pressure Sensor
(Diesel)BK Rear of Intake Manifold 13
Multi-Function Switch On Steering Column 32
Output Speed Sensor DKBL Left Side of Transmission 16
Overdrive Switch On Shift Lever Arm N/S
Overhead Console BK Front of Headliner 25, 26
Oxygen Sensor 1/1 Left Bank
Up (5.9L HD/8.0L)Left Exhaust Manifold Downpipe N/S
Oxygen Sensor 1/1 Upstream
(A/T Except 8.0L)Catalytic Converter Inlet Side N/S
Oxygen Sensor 1/2
Downstream (A/T Except
8.0L)Catalytic Converter Outlet Side N/S
Oxygen Sensor 1/2 Left Bank
Down (California)Catalytic Converter Outlet Side N/S
Oxygen Sensor 1/2
Pre-catalyst (8.0L)Catalytic Converter Inlet Side N/S
Oxygen Sensor 1/3 Post
Catalyst (8.0L)Catalytic Converter Outlet Side N/S
Oxygen Sensor 2/1 Right
Bank Up (5.9L, 5.9HD, 8.0L,
CAL)Right Exhaust Manifold Downpipe N/S
Oxygen Sensor 2/2 Right
Bank Down (California)Catalytic Converter Outlet Side N/S
Oxygen Sensor 1/1 Left Bank
UpLeft Side of Engine N/S
Oxygen Sensor 1/1 Upstream
(M/T Except 8.0L)Catalytic Converter Outlet Side N/S
Park/Neutral Position Switch BK Left Side of Transmission 16
Passenger Airbag At Glove Box 30, 34
Passenger Airbag On/Off
Switch C1Lower Right Side of Instrument Panel 30, 33
Passenger Airbag On/Off
Switch C2Lower Right Side of Instrument Panel 30, 33
Passenger Cylinder Lock
SwitchLTGY In Door N/S
Passenger Door Ajar Switch NAT In Door N/S
Passenger Door Lock Motor BK In Door N/S
Passenger Door Window/
Lock SwitchIn Door N/S
8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONBR/BE
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Passenger Heated Seat
SwitchBL Center of Instrument Panel N/S
Passenger Heated Seat
CushionUnder Seat N/S
Passenger Lumbar Motor Under Seat N/S
Passenger Power Seat Front
Vertical MotorUnder Seat N/S
Passenger Power Seat
Horizontal MotorUnder Seat N/S
Passenger Power Seat Rear
Vertical MotorUnder Seat N/S
Passenger Power Seat
SwitchAt Seat N/S
Passenger Power Window
MotorIn Door N/S
Power Mirror Switch Driver Door 24
Power Outlet BK Center of I.P. 33
Powertrain Control Module
C1BK Right Rear Engine Compartment 1, 3
Powertrain Control Module
C2WT Right Rear Engine Compartment 1, 3
Powertrain Control Module
C3GY Right Rear Engine Compartment 1, 3
Radio Choke Relay BK Instrument Panel Center support 30, 33
Radio C1 GY Rear of Radio 33
Radio C2 BK Rear of Radio 33
Radio C3 BK Instrument Panel Center Support 33
Rear Wheel Speed Sensor
(ABS)BK Left Frame Rail, Near Fuel Tank 27, 29
Right Back-Up Lamp GY Rear of Lamp N/S
Right Fog Lamp WT Rear of Fog Lamp N/S
Right Front Door
Speaker(PremiumBK In Door N/S
Right Front Door
Speaker(StandardBK In Door N/SN/S
Right Front Fender Lamp BK On Fender 27
Right Front Wheel Speed
Sensor (ABS)BK Right Fender Side Shield 22
Right Headlamp BK At Headlamp N/S
Right License Lamp BK At Rear Bumper N/S
Right Outboard Clearance
LampBK Behind Front of Headliner 25
Right Outboard Headlamp At Headlamp N/S
Right Outboard Identification
LampBK Behind Front of Headliner 25
BR/BE8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

If a vehicle will be stored for more than about thirty
days, the battery negative cable should be discon-
nected to eliminate normal IOD; and, the battery
should be tested and recharged at regular intervals
during the vehicle storage period to prevent the bat-
tery from becoming discharged or damaged. Refer to
theBatterysection of the service manual for the
location of additional service information covering
the battery.
REMOVAL
The Ignition-Off Draw (IOD) fuse is disconnected
from Junction Block (JB) fuse cavity 12 when the
vehicle is shipped from the assembly plant. Dealer
personnel must reconnect the IOD fuse when the
vehicle is being prepared for delivery in order to
restore full electrical system operation.
(1) Turn the ignition switch to the Off position.
(2) Remove the fuse access panel by unsnapping it
from the left outboard end of the instrument panel.
(3) Grasp the upper and lower tabs of the IOD
fuse holder unit in fuse cavity 12 (Fig. 4) of the JB
between the thumb and forefinger and pull the unit
firmly outward.
(4) Install the fuse access panel by snapping it
onto the left outboard end of the instrument panel.
INSTALLATION
The Ignition-Off Draw (IOD) fuse is disconnected
from Junction Block (JB) fuse cavity 12 when the
vehicle is shipped from the assembly plant. Dealer
personnel must reconnect the IOD fuse when the
vehicle is being prepared for delivery in order to
restore full electrical system operation.
(1) Turn the ignition switch to the Off position.
(2) To install the IOD fuse, use a thumb to press
the IOD fuse holder unit in fuse cavity 12 firmly into
the JB.
(3) Install the fuse access panel by snapping it
onto the left outboard end of the instrument panel.
JUNCTION BLOCK
DESCRIPTION
An electrical Junction Block (JB) is concealed
behind the left outboard end of the instrument panel
cover (Fig. 5). The JB combines the functions previ-
ously provided by a separate fuseblock module and
relay center, serves to simplify and centralize numer-
ous electrical components, and to distribute electrical
current to many of the accessory systems in the vehi-
cle. It also eliminates the need for numerous splice
connections and serves in place of a bulkhead connec-
Fig. 4 Ignition-Off Draw Fuse
1 - JUNCTION BLOCK
2 - IGNITION-OFF DRAW FUSE AND HOLDER
3 - LEFT INSTRUMENT PANEL END BRACKETFig. 5 Junction Block Location
1 - JUNCTION BLOCK
2 - FUSE ACCESS PANEL
8W - 97 - 6 8W-97 POWER DISTRIBUTIONBR/BE
IOD FUSE (Continued)

CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
AIR ESCAPES THROUGH
THROTTLE BODYIntake valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
TAILPIPEExhaust valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
RADIATORHead gasket leaking or cracked
cylinder head or blockRemove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERSHead gasket leaking or crack in
cylinder head or block between
adjacent cylindersRemove cylinder head and inspect.
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLYStuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wallInspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN II
MopartEngine RTV GEN II is used to seal com-
ponents exposed to engine oil. This material is a spe-
cially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTV
MopartATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic transmission fluid, engine coolants, and
moisture. This material is available in three ouncetubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKER
MopartGasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARtGASKET SEALANT
MopartGasket Sealant is a slow drying, perma-
nently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage
of oil and coolant. Can be used on threaded and
machined parts under all temperatures. This mate-
rial is used on engines with multi-layer steel (MLS)
cylinder head gaskets. This material also will pre-
vent corrosion. MopartGasket Sealant is available in
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
9 - 10 ENGINE 5.9LBR/BE
ENGINE 5.9L (Continued)

(13) Disconnect the heater hoses and bypass hose.
(14) Remove the closed crankcase ventilation and
evaporation control systems.
(15) Remove intake manifold bolts.
(16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear end seals.
(18) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 65). Dis-
card the gasket.
(19) If required, remove the plenum pan and gas-
ket. Discard gasket.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) If removed, position new plenum gasket and
install plenum pan (Fig. 66).
(2) Tighten plenum pan mounting bolts as follows:²Step 1. Tighten bolts to 5.4 N´m (48 in. lbs.)
²Step 2. Tighten bolts to 9.5 N´m (84 in. lbs.)
²Step 3. Check all bolts are at 9.5 N´m (84 in.
lbs.)
(3) Install the flange gaskets. Ensure that the ver-
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs
(Fig. 68). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
(4) Apply MopartGEN II Silicone Rubber Adhe-
sive Sealant, or equivalent, to the four corner joints.
An excessive amount of sealant is not required to
ensure a leak proof seal. However, an excessive
amount of sealant may reduce the effectiveness of
the flange gasket. The sealant should be approxi-
mately 5 mm (0.2 in) in diameter and 15 mm (0.6 in.)
long.
(5) Install the front and rear end seals (Fig. 67)
Make sure the molded dowel pins on the end seals
fully enter the corresponding holes in the cylinder
block.
(6) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. After intake
manifold is in place, inspect to make sure seals are
in place.
(7) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23 N´m
(200 in. lbs.) torque.
(8) Install the intake manifold bolts and tighten as
follows (Fig. 69):
Fig. 65 Throttle Body Assembly
1 - FUEL RAIL ASSEMBLY
2 - FUEL RAIL MOUNTING BOLTS
3 - FUEL RAIL CONNECTING HOSES
Fig. 66 Plenum Pan Bolt Tightening Sequence
BR/BEENGINE 5.9L 9 - 51
INTAKE MANIFOLD (Continued)