relay DODGE RAM 2002 Service Repair Manual

(4) Press firmly on the cigar lighter or power out-
let receptacle base until the retaining bosses of the
mount are fully engaged in their receptacles.
(5) Install the cigar lighter knob and element into
the cigar lighter receptacle base, or the protective cap
into the power outlet receptacle base.
(6) Reconnect the battery negative cable.
HORN RELAY
DESCRIPTION
The horn relay is a International Standards Orga-
nization (ISO) micro-relay. The terminal designations
and functions are the same as a conventional ISO
relay. However, the micro-relay terminal orientation
(or footprint) is different, current capacity is lower,
and the relay case dimensions are smaller than those
of the conventional ISO relay.
The horn relay is a electromechanical device that
switches battery current to the horn when the horn
switch or when the high-line or premium Central
Timer Module (CTM) grounds the relay coil. See
Horn Relay in the Diagnosis and Testing section of
this group for more information.
The horn relay is located in the Power Distribution
Center (PDC), in the engine compartment. Refer to
the PDC label for relay identification and location.
If a problem is encountered with a continuously
sounding horn, it can usually be quickly resolved by
removing the horn relay from the PDC until further
diagnosis is completed.
The horn relay cannot be repaired and, if faulty or
damaged, it must be replaced.
DIAGNOSIS AND TESTING - HORN RELAY
The headlamp (or security) relay and the horn
relay are located in the Power Distribution Center
(PDC) in the engine compartment. Each of these
relays can be tested as described in the following pro-
cedure, however the circuits they are used in do vary.
To test the relay circuits, refer to the circuit descrip-
tions and diagrams in Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO THE RESTRAINTS SECTION OF
THE SERVICE MANUAL BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.Remove the relay (Fig. 13) from the PDC as
described in this group to perform the following tests:
(1) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 2. If not OK, replace the faulty relay.
(2) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75   5 ohms. If OK, go to Step
3. If not OK, replace the faulty relay.
(3) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, test the relay circuits. If not OK,
replace the faulty relay.REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cover from the Power Distribution
Center (PDC) (Fig. 14).
(3) Refer to the label on the PDC for horn relay
identification and location.
(4) Unplug the horn relay from the PDC.
INSTALLATION
(1) Install the horn relay by aligning the relay ter-
minals with the cavities in the PDC and pushing the
relay firmly into place.
(2) Install the PDC cover.
(3) Connect the battery negative cable.
(4) Test the relay operation.
Fig. 13 Relay Terminals
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
8W - 97 - 12 8W-97 POWER DISTRIBUTIONBR/BE
POWER OUTLET (Continued)

HEADLAMP RELAY
DESCRIPTION
The headlamp (or security) relay is a International
Standards Organization (ISO) micro-relay. The termi-
nal designations and functions are the same as a con-
ventional ISO relay. However, the micro-relay
terminal orientation (or footprint) is different, cur-
rent capacity is lower, and the relay case dimensions
are smaller than those of the conventional ISO relay.
The headlamp relay is a electromechanical device
that switches battery current to the headlamps when
the high-line or premium Central Timer Module
(CTM) grounds the relay coil. See Headlamp Relay in
the Diagnosis and Testing section of this group for
more information.
The headlamp (or security) relay is located in the
Power Distribution Center (PDC), in the engine com-
partment. Refer to the PDC label for relay identifica-
tion and location.
The headlamp relay cannot be repaired and, if
faulty or damaged, it must be replaced.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cover from the Power Distribution
Center (PDC) (Fig. 15).
(3) Refer to the label on the PDC for headlamp (or
security) relay identification and location.
(4) Unplug the headlamp relay from the PDC.
INSTALLATION
(1) Install the headlamp relay by aligning the
relay terminals with the cavities in the PDC and
pushing the relay firmly into place.(2) Install the PDC cover.
(3) Connect the battery negative cable.
(4) Test the relay operation.
MICRO-RELAY
DESCRIPTION
A micro-relay is a conventional International Stan-
dards Organization (ISO) micro relay (Fig. 16).
Relays conforming to the ISO specifications have
common physical dimensions, current capacities, ter-
minal patterns, and terminal functions. The relay is
Fig. 14 Power Distribution Center
1 - COVER
2 - POWER DISTRIBUTION CENTER
Fig. 15 Power Distribution Center
1 - COVER
2 - POWER DISTRIBUTION CENTER
Fig. 16 ISO MICRO RELAY
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
BR/BE8W-97 POWER DISTRIBUTION 8W - 97 - 13
HORN RELAY (Continued)

contained within a small, rectangular, molded plastic
housing and is connected to all of the required inputs
and outputs by five integral male spade-type termi-
nals that extend from the bottom of the relay base.
Relays cannot be adjusted or repaired and, if faulty
or damaged, the unit must be replaced.
OPERATION
A micro-relay is an electromechanical switch that
uses a low current input from one source to control a
high current output to another device. The movable
common feed contact point is held against the fixed
normally closed contact point by spring pressure.
When the relay coil is energized, an electromagnetic
field is produced by the coil windings. This electro-
magnetic field draws the movable relay contact point
away from the fixed normally closed contact point,
and holds it against the fixed normally open contact
point. When the relay coil is de-energized, spring
pressure returns the movable contact point back
against the fixed normally closed contact point. A
resistor is connected in parallel with the relay coil in
the relay, and helps to dissipate voltage spikes and
electromagnetic interference that can be generated as
the electromagnetic field of the relay coil collapses.
DIAGNOSIS AND TESTING - MICRO-RELAY
(1) Remove the relay from its mounting location.
(2) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 67.5 - 82.5 ohms. If OK, go to
Step 4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, reinstall the relay and use a DRBIIIt
scan tool to perform further testing. Refer to the
appropriate diagnostic information.
Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
harness routing and retention, connector pin-out
information and location views for the various wire
harness connectors, splices and grounds.
REMOVAL
(1) Remove the relay by grasping it firmly and
pulling it straight out from its receptacle.
INSTALLATION
(1) Align the micro-relay terminals with the termi-
nal cavities in the receptacle.(2) Push firmly and evenly on the top of the relay
until the terminals are fully seated in the terminal
cavities in the receptacle.
RELAY
DESCRIPTION
A relay is an electromechanical device that
switches fused battery current to a electrical compo-
nent when the ignition switch is turned to the Acces-
sory or Run positions, or when controlled by a
electronic module. The relays are located in the junc-
tion block or power distribution center (Fig. 17).
The relay is a International Standards Organiza-
tion (ISO) relay. Relays conforming to the ISO speci-
fications have common physical dimensions, current
capacities, terminal patterns, and terminal functions.
A relay cannot be repaired or adjusted and, if
faulty or damaged, it must be replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor and three (two fixed and one movable) elec-
trical contacts. The movable (common feed) relay con-
tact is held against one of the fixed contacts
(normally closed) by spring pressure. When the elec-
tromagnetic coil is energized, it draws the movable
contact away from the normally closed fixed contact,
and holds it against the other (normally open) fixed
contact.
When the electromagnetic coil is de-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor is connected in
parallel with the electromagnetic coil in the relay,
and helps to dissipate voltage spikes that are pro-
duced when the coil is de-energized.
Fig. 17 TYPE 1 RELAY
8W - 97 - 14 8W-97 POWER DISTRIBUTIONBR/BE
MICRO-RELAY (Continued)

DIAGNOSIS AND TESTING - RELAY
The relays are located in the junction block or
power distribution center. For complete circuit dia-
grams, refer toWiring Diagrams.
(1) Remove the relay from its mounting location.
(2) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 60.7 - 80.3 ohms. If OK, go to
Step 4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, perform the Relay Circuit Test that
follows. If not OK, replace the faulty relay.
DIAGNOSIS AND TESTING - RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) of
the junction block or power distribution center is con-
nected to battery voltage and should be hot at all
times. Check for battery voltage at the fused B(+) cir-
cuit cavity in the junction block receptacle for the
relay. If OK, go to Step 2. If not OK, repair the fused
B(+) circuit to the Power Distribution Center (PDC)
fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the fused B(+) fuse in the junction block that feedsthe accessory when the relay is energized by the igni-
tion switch. There should be continuity between the
junction block cavity for relay terminal 87 and the
fused B(+) fuse in the junction block at all times. If
OK, go to Step 4. If not OK, repair the open fused
B(+) circuit to the junction block fuse as required.
(4) The coil ground terminal (85) is connected to
the electromagnet in the relay. It receives battery
feed to energize the relay when the ignition switch is
in the Accessory or Run positions. Turn the ignition
switch to the On position. Check for battery voltage
at the fused ignition switch output (acc/run) circuit
cavity for relay terminal 85 in the junction block
receptacle for the relay. If OK, go to Step 5. If not
OK, repair the open fused ignition switch output
(acc/run) circuit to the ignition switch as required.
(5) The coil battery terminal (86) is connected to
the electromagnet in the relay. The junction block
cavity for this terminal should have continuity to
ground at all times. If not OK, repair the open
ground circuit to ground as required.
REMOVAL
(1) Remove the relay by grasping it firmly and
pulling it straight out from its receptacle.
INSTALLATION
(1) Position the relay to the proper receptacle.
(2) Align the relay terminals with the terminal
cavities in the receptacle.
(3) Push firmly and evenly on the top of the relay
until the terminals are fully seated in the terminal
cavities in the receptacle.
BR/BE8W-97 POWER DISTRIBUTION 8W - 97 - 15
RELAY (Continued)

(4) Connect the 0-414 kPa (0-60 psi) fuel pressure
test gauge (from Gauge Set 5069) to the test port on
the appropriate Adaptor Tool.The DRBtIII Scan
Tool along with the PEP module, the 500 psi
pressure transducer, and the transducer-to-test
port adapter may also be used in place of the
fuel pressure gauge.
The fittings on both tools must be in good
condition and free from any small leaks before
performing the proceeding test.
(5) Start engine and bring to normal operating
temperature.
(6) Observe test gauge. Normal operating pressure
should be 339 kPa +/±34 kPa (49.2 psi +/±5 psi).
(7) Shut engine off.
(8) Pressure should not fall below30 psi for five
minutes.
(9) If pressure falls below 30 psi, it must be deter-
mined if a fuel injector, the check valve within the
fuel pump module, or a fuel tube/line is leaking.
(10) Again, start engine and bring to normal oper-
ating temperature.
(11) Shut engine off.
(12)Testing for fuel injector or fuel rail leak-
age:Clamp off the rubber hose portion of Adaptor
Tool between the fuel rail and the test port ªTº on
Adapter Tool. If pressure now holds at or above 30
psi, a fuel injector or the fuel rail is leaking.
(13)Testing for fuel pump check valve, filter/
regulator check valve or fuel tube/line leakage:
Clamp off the rubber hose portion of Adaptor Tool
between the vehicle fuel line and test port ªTº on
Adapter Tool. If pressure now holds at or above 30
psi, a leak may be found at a fuel tube/line. If no
leaks are found at fuel tubes or lines, one of the
check valves in either the electric fuel pump or filter/
regulator may be leaking.
Note: A quick loss of pressure usually indicates a
defective check valve in the filter/regulator. A slow
loss of pressure usually indicates a defective check
valve in the electric fuel pump.
The electric fuel pump is not serviced separately.
Replace the fuel pump module assembly. The filter/
regulator may be replaced separately on certain
applications. Refer to Fuel Filter/Fuel Pressure Reg-
ulator Removal/Installation for additional informa-
tion.
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fill cap.(2) Remove fuel pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(3) Start and run engine until it stalls.
(4) Attempt restarting engine until it will no
longer run.
(5) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unplug connector from any fuel injector.
(7) Attach one end of a jumper wire with alligator
clips (18 gauge or smaller) to either injector terminal.
(8) Connect other end of jumper wire to positive
side of battery.
(9) Connect one end of a second jumper wire to
remaining injector terminal.
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentarily touch other end of jumper wire
to negative terminal of battery for no more than a
few seconds.
(11) Place a rag or towel below fuel line quick-con-
nect fitting at fuel rail.
(12) Disconnect quick-connect fitting at fuel rail.
Refer to Quick-Connect Fittings.
(13) Return fuel pump relay to PDC.
(14) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRBtscan tool must be
used to erase a DTC.
SPECIFICATIONS
SPECIFICATIONS - FUEL SYSTEM PRESSURE -
GAS ENGINES
All Gasoline Powered Engines:339 kPa   34
kPa (49.2 psi   5 psi)
BR/BEFUEL DELIVERY - GASOLINE 14 - 3
FUEL DELIVERY - GASOLINE (Continued)

FUEL PUMP
DESCRIPTION
The electric fuel pump is located inside of the fuel
pump module. A 12 volt, permanent magnet, electric
motor powers the fuel pump. The electric fuel pump
is not a separate, serviceable component.
OPERATION
Voltage to operate the electric pump is supplied
through the fuel pump relay.
Fuel is drawn in through a filter at the bottom of
the module and pushed through the electric motor
gearset to the pump outlet.
Check Valve Operation:The pump outlet con-
tains a one-way check valve to prevent fuel flow back
into the tank and to maintain fuel supply line pres-
sure (engine warm) when pump is not operational. It
is also used to keep the fuel supply line full of gaso-
line when pump is not operational. After the vehicle
has cooled down, fuel pressure may drop to 0 psi
(cold fluid contracts), but liquid gasoline will remain
in fuel supply line between the check valve and fuel
injectors.Fuel pressure that has dropped to 0
psi on a cooled down vehicle (engine off) is a
normal condition.Refer to the Fuel Pressure Leak
Down Test for more information.
The electric fuel pump is not a separate, service-
able component.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FUEL PUMP
CAPACITY TEST
Before performing this test, verify fuel pump
pressure. Refer to Fuel Pump Pressure Test.
Use this test in conjunction with the Fuel Pres-
sure Leak Down Test.
(1) Release fuel system pressure. Refer to Fuel
Pressure Release Procedure.
(2) Disconnect fuel supply line at fuel rail. Refer to
Quick-Connect Fittings. Some engines may require
air cleaner housing removal before line disconnection.
(3) Obtain correct Fuel Line Pressure Test Adapter
Tool Hose. Tool number 6539 is used for 5/16º fuel
lines and tool number 6631 is used for 3/8º fuel lines.
(4) Connect correct Fuel Line Pressure Test
Adapter Tool Hose into disconnected fuel supply line.
Insert other end of Adaptor Tool Hose into a gradu-
ated container.
(5) Remove fuel fill cap.
(6) To activate fuel pump and pressurize system,
obtain DRBtscan tool and actuate ASD Fuel System
Test.(7) A good fuel pump will deliver at least 1/4 liter
of fuel in 7 seconds. Do not operate fuel pump for
longer than 7 seconds with fuel line disconnected as
fuel pump module reservoir may run empty.
(a) If capacity is lower than specification, but
fuel pump can be heard operating through fuel fill
cap opening, check for a kinked/damaged fuel sup-
ply line somewhere between fuel rail and fuel
pump module.
(b) If line is not kinked/damaged, and fuel pres-
sure is OK, but capacity is low, replace fuel filter/
fuel pressure regulator. The filter/regulator may be
serviced separately on certain applications. Refer
to Fuel Filter/Fuel Pressure Regulator Removal/In-
stallation for additional information.
(c) If both fuel pressure and capacity are low,
replace fuel pump module assembly. Refer to Fuel
Pump Module Removal/Installation.
DIAGNOSIS AND TESTING - FUEL PUMP
PRESSURE TEST
Use this test in conjunction with the Fuel Pump
Capacity Test, Fuel Pressure Leak Down Test and
Fuel Pump Amperage Test found elsewhere in this
group.
Check Valve Operation:The electric fuel pump
outlet contains a one-way check valve to prevent fuel
flow back into the tank and to maintain fuel supply
line pressure (engine warm) when pump is not oper-
ational. It is also used to keep the fuel supply line
full of gasoline when pump is not operational. After
the vehicle has cooled down, fuel pressure may drop
to 0 psi (cold fluid contracts), but liquid gasoline will
remain in fuel supply line between the check valve
and fuel injectors.Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition.When the elec-
tric fuel pump is activated, fuel pressure should
immediately(1±2 seconds) rise to specification.
All fuel systems are equipped with a fuel tank
module mounted, combination fuel filter/fuel pressure
regulator. The fuel pressure regulator is not con-
trolled by engine vacuum.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. BEFORE DISCONNECTING FUEL LINE AT
FUEL RAIL, THIS PRESSURE MUST BE RELEASED.
REFER TO THE FUEL SYSTEM PRESSURE
RELEASE PROCEDURE.
(1) Remove protective cap at fuel rail test port.
Connect the 0±414 kPa (0-60 psi) fuel pressure gauge
(from gauge set 5069) to test port pressure fitting on
fuel rail (Fig. 11).The DRBtIII Scan Tool along
with the PEP module, the 500 psi pressure
BR/BEFUEL DELIVERY - GASOLINE 14 - 9

transducer, and the transducer-to-test port
adapter may also be used in place of the fuel
pressure gauge.
(2) Start and warm engine and note pressure
gauge reading. Fuel pressure should be 339 kPa   34
kPa (49.2 psi   5 psi) at idle.
(3) If engine runs, but pressure is below 44.2 psi,
check for a kinked fuel supply line somewhere
between fuel rail and fuel pump module. If line is not
kinked, but specifications for either the Fuel Pump
Capacity, Fuel Pump Amperage or Fuel Pressure
Leak Down Tests were not met, replace fuel pump
module assembly. Refer to Fuel Pump Module
Removal/Installation.
(4) If operating pressure is above 54.2 psi, electric
fuel pump is OK, but fuel pressure regulator is defec-
tive. Replace fuel filter/fuel pressure regulator. Refer
to Fuel Filter/Fuel Pressure Regulator Removal/In-
stallation for more information.
(5) Install protective cap to fuel rail test port.
DIAGNOSIS AND TESTING - FUEL PUMP
AMPERAGE TEST
This amperage (current draw) test is to be done in
conjunction with the Fuel Pump Pressure Test, Fuel
Pump Capacity Test and Fuel Pressure Leak Down
Test. Before performing the amperage test, be sure
the temperature of the fuel tank is above 50É F (10É
C).
The DRBtScan Tool along with the DRB Low Cur-
rent Shunt (LCS) adapter (Fig. 12) and its test leads
will be used to check fuel pump amperage specifica-
tions.(1) Be sure fuel tank contains fuel before starting
test. If tank is empty or near empty, amperage read-
ings will be incorrect.
(2) Obtain LCS adapter.
(3) Plug cable from LCS adapter into DRB scan
tool at SET 1 receptacle.
(4) Plug DRB into vehicle 16±way connector (data
link connector).
(5) Connect (-) and (+) test cable leads into LCS
adapter receptacles. Use10 amp (10A +)receptacle
and common (-) receptacles.
(6) Gain access to MAIN MENU on DRB screen.
(7) Press DVOM button on DRB.
(8) Using left/right arrow keys, highlight CHAN-
NEL 1 function on DRB screen.
(9) Press ENTER three times.
(10) Using up/down arrow keys, highlight RANGE
on DRB screen (screen will default to 2 amp scale).
(11) Press ENTER to change 2 amp scale to 10
amp scale.This step must be done to prevent
damage to DRB scan tool or LCS adapter
(blown fuse).
(12) Remove cover from Power Distribution Center
(PDC).
(13) Remove fuel pump relay from PDC. Refer to
label on PDC cover for relay location.
Fig. 11 FUEL PRESSURE TEST GAUGE (TYPICAL
GAUGE INSTALLATION AT TEST PORT)
1 - SERVICE (TEST) PORT
2 - FUEL PRESSURE TEST GAUGE
3 - FUEL RAIL
Fig. 12 LOW CURRENT SHUNT
1 - LOW CURRENT SHUNT ADAPTER
2 - PLUG TO DRB
3 - TEST LEAD RECEPTACLES
14 - 10 FUEL DELIVERY - GASOLINEBR/BE
FUEL PUMP (Continued)

WARNING: BEFORE PROCEEDING TO NEXT STEP,
NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI-
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND
FUEL SYSTEM COMPONENTS ARE CONNECTED.
CAUTION: To prevent possible damage to the vehi-
cle electrical system and LCS adapter, the test
leads must be connected into relay cavities exactly
as shown in following steps.
Depending upon vehicle model, year or engine con-
figuration, three different types of relays may be
used: Type-1, type-2 and type±3.
(14) If equipped withtype±1 relay(Fig. 13),
attach test leads from LCS adapter into PDC relay
cavities number 30 and 87. For location of these cav-
ities, refer to numbers stamped to bottom of relay
(Fig. 13).
(15) If equipped withtype±2 relay(Fig. 14),
attach test leads from LCS adapter into PDC relay
cavities number 30 and 87. For location of these cav-
ities, refer to numbers stamped to bottom of relay
(Fig. 14).
(16) If equipped withtype±3 relay(Fig. 15),
attach test leads from LCS adapter into PDC relay
cavities number 3 and 5. For location of these cavi-
ties, refer to numbers stamped to bottom of relay
(Fig. 15).
(17) When LCS adapter test leads are attached
into relay cavities, fuel pumpwill be activated.
Determine fuel pump amperage on DRB screen.
Amperage should be below 10.0 amps. If amperage is
below 10.0 amps, and specifications for the Fuel
Pump Pressure, Fuel Pump Capacity and Fuel Pres-
sure Leak Down tests were met, the fuel pump mod-
ule is OK.
(18) If amperage is more than 10.0 amps, replace
fuel pump module assembly. The electric fuel pump
is not serviced separately.
(19) Disconnect test leads from relay cavities
immediately after testing.
Fig. 13 FUEL PUMP RELAY - TYPE 1
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 14 FUEL PUMP RELAY - TYPE 2
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
BR/BEFUEL DELIVERY - GASOLINE 14 - 11
FUEL PUMP (Continued)

FUEL PUMP MODULE
DESCRIPTION
The fuel pump module on all gas powered engines
is installed in the top of the fuel tank (Fig. 16) or
(Fig. 17). The fuel pump module (Fig. 16), (Fig. 17)or
(Fig. 18)contains the following:
²A combination fuel filter/fuel pressure regulator
²Electric fuel pump
²Fuel pump reservoir
²A separate in-tank fuel filter (at bottom of mod-
ule)
²Check valve (certain modules)
²Fuel gauge sending unit (fuel level sensor)
²Fuel supply line connection at filter/regulator
²A threaded locknut retaining pump module to
fuel tank
²A gasket between tank flange and module
²Auxiliary non-pressurized fuel supply fitting (not
all engines)
The fuel gauge sending unit (fuel level sensor), and
pick-up filter (at bottom of module) may be serviced
separately. If the electrical fuel pump requires ser-
vice, the entire fuel pump module must be replaced.
The fuel filter/fuel pressure regulator may be ser-
viced separately. Refer to Fuel Filter/Fuel Pressure
Regulator Removal/Installation for additional infor-
mation.
Fig. 15 FUEL PUMP RELAY - TYPE 3
TERMINAL LEGEND
NUMBER IDENTIFICATION
1 COIL BATTERY
2 COIL GROUND
3 COMMON FEED
4 NORMALLY CLOSED
5 NORMALLY OPEN
Fig. 16 Fuel Pump Module - Gas Powered With 26
or 34 Gallon Tank±Typical
1 - FUEL FILTER/PRESSURE REGULATOR
2 - FUEL SUPPLY FITTING
3 - REAR FUEL TANK CHECK VALVE
4 - ELECTRICAL CONNECTOR
5 - FUEL PUMP MODULE
6 - FRONT FUEL TANK CHECK VALVE
7 - LOCKNUT
Fig. 17 Fuel Pump Module - Gas Powered with 35
Gal. Tank
1 - FUEL FILTER/PRESSURE REGULATOR
2 - FUEL SUPPLY FITTING
3 - ELECTRICAL CONNECTOR
4 - LOCKNUT
5 - FUEL PUMP MODULE
6 - AUXILIARY CAPPED FITTING
14 - 12 FUEL DELIVERY - GASOLINEBR/BE
FUEL PUMP (Continued)

FUEL INJECTION - GASOLINE
TABLE OF CONTENTS
page page
FUEL INJECTION - GASOLINE
DIAGNOSIS AND TESTING
VISUAL INSPECTIONÐ5.9L ENGINES.....29
VISUAL INSPECTIONÐ8.0L ENGINE......32
SPECIFICATIONS - TORQUE - GAS FUEL
INJECTION..........................35
SPECIAL TOOLS
FUEL SYSTEM.......................35
ACCELERATOR PEDAL
REMOVAL.............................36
INSTALLATION.........................37
CRANKSHAFT POSITION SENSOR
DESCRIPTION
DESCRIPTION - 5.9L...................37
DESCRIPTION - 8.0L...................37
OPERATION
OPERATION - 5.9L....................37
OPERATION - 8.0L....................38
REMOVAL
REMOVAL - 5.9L......................38
REMOVAL - 8.0L......................39
INSTALLATION
INSTALLATION - 5.9L..................39
INSTALLATION - 8.0L..................39
FUEL PUMP RELAY
DESCRIPTION.........................40
OPERATION...........................40
REMOVAL.............................40
INSTALLATION.........................40
IDLE AIR CONTROL MOTOR
DESCRIPTION.........................40
OPERATION...........................40
REMOVAL
REMOVAL - 5.9L......................41
REMOVAL - 8.0L......................41
INSTALLATION
INSTALLATION - 5.9L..................42
INSTALLATION - 8.0L..................42
INTAKE AIR TEMPERATURE SENSOR
DESCRIPTION - 5.9L/8.0L.................42
OPERATION - 5.9L/8.0L..................42
REMOVAL
REMOVAL - 5.9L......................42
REMOVAL - 8.0L......................43
INSTALLATION
INSTALLATION - 5.9L..................43
INSTALLATION - 8.0L..................43MANIFOLD ABSOLUTE PRESSURE SENSOR
DESCRIPTION - 5.9L/8.0L.................43
OPERATION - 5.9L/8.0L..................43
REMOVAL
REMOVAL - 5.9L......................44
REMOVAL - 8.0L......................44
INSTALLATION
INSTALLATION - 5.9L..................45
INSTALLATION - 8.0L..................45
O2 SENSOR
DESCRIPTION.........................45
OPERATION...........................45
REMOVAL.............................46
INSTALLATION.........................47
PTO SWITCH
DESCRIPTION.........................47
OPERATION...........................47
THROTTLE BODY
DESCRIPTION.........................47
OPERATION...........................47
REMOVAL
REMOVAL - 5.9L......................47
REMOVAL - 8.0L......................47
INSTALLATION
INSTALLATION - 5.9L..................48
INSTALLATION - 8.0L..................49
THROTTLE CONTROL CABLE
REMOVAL.............................49
INSTALLATION.........................50
THROTTLE POSITION SENSOR
DESCRIPTION.........................50
OPERATION...........................50
REMOVAL
REMOVAL - 5.9L......................50
REMOVAL - 8.0L......................50
INSTALLATION
INSTALLATION - 5.9L..................51
INSTALLATION - 8.0L..................51
FUEL INJECTOR
DESCRIPTION.........................52
OPERATION
OPERATION.........................52
OPERATION - PCM OUTPUT............52
DIAGNOSIS AND TESTING - FUEL INJECTOR . 53
REMOVAL.............................53
INSTALLATION.........................53
14 - 28 FUEL INJECTION - GASOLINEBR/BE