light DODGE RAM 2002 Service Repair Manual

HEAT SHIELDS
DESCRIPTION
There are two types of heat shields used. One is
stamped steel the other is molded foil sheets. The
shields attach to the vehicle around the exhaust sys-
tem to prevent heat from the exhaust system from
entering the passenger area and other areas where
the heat can cause damage to other components.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the nuts or bolts holding the exhaust
heat shield to the floor pan, crossmember or bracket.
(3) Slide the shield out around the exhaust system.
INSTALLATION
(1) Position the exhaust heat shield to the floor
pan, crossmember or bracket and install the nuts or
bolts.
(2) Tighten the nuts and bolts 11 N´m (100 in.
lbs.).
(3) Lower the vehicle.
MUFFLER - 3.9L/5.2L/5.9L/8.0L
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
(3) Disconnect the muffler hanger (Fig. 12) (Fig.
13).
(4) Remove clamps and nuts (Fig. 12) (Fig. 13).
(5) Remove the muffler.
INSTALLATION
(1) Assemble muffler and clamps loosely to permit
proper alignment of all parts.
(2) Connect the muffler hanger.
(3) Tighten the clamp nuts to 48 N´m (35 ft. lbs.)
torque.
(4) Lower the vehicle.
(5) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels. A
minimum of 25.4 mm (1.0 in.) is required between
exhaust system components and body/frame parts.
Adjust the alignment, if needed.
Fig. 12 Muffler for 3.9L, 5.2L and 5.9L-Light Duty Engines
1 - TAILPIPE
2 - CLAMP3 - MUFFLER LIGHT DUTY
11 - 10 EXHAUST SYSTEMBR/BE

(4) Discharge the A/C system (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE) and remove the A/C condenser
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - REMOVAL) (Fig.
31) (if A/C equipped).
(5) Remove the transmission auxiliary cooler (Fig.
31) (Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER - REMOVAL).
(6) Remove the boost tubes from the charge air
cooler (Fig. 32).
(7) Remove the charge air cooler bolts. Pivot the
charge air cooler forward and up to remove.
CLEANING
CAUTION: Do not use caustic cleaners to clean the
charge air cooler. Damage to the charge air cooler
will result.
NOTE: If internal debris cannot be removed from
the cooler, the charge air cooler MUST be replaced.
(1) If the engine experiences a turbocharger failure
or any other situation where oil or debris get into the
charge air cooler, the charge air cooler must be
cleaned internally.
(2) Position the charge air cooler so the inlet and
outlet tubes are vertical.
(3) Flush the cooler internally with solvent in the
direction opposite of normal air flow.(4) Shake the cooler and lightly tap on the end
tanks with a rubber mallet to dislodge trapped
debris.
(5) Continue flushing until all debris or oil are
removed.
(6) Rinse the cooler with hot soapy water to
remove any remaining solvent.
(7) Rinse thoroughly with clean water and blow
dry with compressed air.
INSPECTION
Visually inspect the charge air cooler for cracks,
holes, or damage. Inspect the tubes, fins, and welds
for tears, breaks, or other damage. Replace the
charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge
Air Cooler Tester Kit #3824556. This kit is available
through CumminstService Products. Instructions
are provided with the kit.
Fig. 31 Condenser and Transmission Auxiliary
Cooler
1 - A/C CONDENSOR
2 - TRANSMISSION COOLER
3 - INTERCOOLER
Fig. 32 Air Intake System Tubes
1 - CLAMP
2 - INTERCOOLER INLET DUCT
3 - CLAMP
4 - VALVE COVER
5 - AIR INLET HOUSING
6 - CLAMP
7 - INTERCOOLER OUTLET DUCT
8 - CLAMP
9 - INTERCOOLER
BR/BEEXHAUST SYSTEM 11 - 19
CHARGE AIR COOLER AND PLUMBING (Continued)

FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
DESCRIPTION..........................1
SPECIFICATIONS - TORQUE...............1
FRONT AIR DAM
REMOVAL.............................2
INSTALLATION..........................2
FRONT FASCIA
REMOVAL.............................2
INSTALLATION..........................2
ADJUSTMENTS
ADJUSTMENT.........................2
FRONT LOWER FASCIA
REMOVAL.............................3
INSTALLATION..........................3
FRONT FASCIA - SPORT
REMOVAL.............................3
INSTALLATION..........................3
FRONT BUMPER
REMOVAL.............................4
INSTALLATION..........................4
FRONT BUMPER - SPORT
REMOVAL.............................5INSTALLATION..........................5
REAR BUMPER
REMOVAL.............................6
INSTALLATION..........................6
FRAME
DESCRIPTION
DESCRIPTION........................6
FRAME SERVICE......................7
SPECIFICATIONS
FRAME DIMENSION....................8
CAB CHASSIS ADAPTER BRACKET
REMOVAL.............................10
INSTALLATION.........................10
FRONT TOW HOOK
REMOVAL.............................10
INSTALLATION.........................10
TRAILER HITCH
REMOVAL.............................11
INSTALLATION.........................11
TRANSFER CASE SKID PLATE
REMOVAL.............................11
INSTALLATION.........................11
BUMPERS
DESCRIPTION
Bumpers are used at the front and rear of the
vehicle. Bumpers may be chrome or painted.Bumpers are designed to protect the exterior sheet-
metal in low impact situations. The bumpers are
attached to the frame and provide mounting points
for some optional accessories such as fog lights and
tow hooks.
SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Cab chassis adapter nut 108 80 Ð
Front bumper bracket to frame nut 68 50 Ð
Front bumper outer brace bolt 68 50 Ð
Rear bumper to brace nut 40 30 Ð
Rear bumper brace to bracket nut 101 75 Ð
Rear bumper bracket to frame nut 101 75 Ð
Skid plate crossmember to frame bolt 54 40 Ð
Skid plate to crossmember bolt 40 30 Ð
Skid plate to transmission crossmember bolt 54 40 Ð
Spare tire winch bolt 27 20 Ð
Trailer hitch nut 108 80 Ð
BR/BEFRAME & BUMPERS 13 - 1

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)

(5) Push therightfuel rail down until fuel injec-
tors have bottomed on injector shoulder. Push the
leftfuel rail down until fuel injectors have bottomed
on injector shoulder.
(6) Install fuel rail mounting bolts.
(7) Connect electrical connector to intake manifold
air temperature sensor.
(8) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 26). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector.
(9) Install the A/C support bracket (if equipped).
(10) Install throttle body to intake manifold. Refer
to Throttle Body installation in this section of the
group.
(11) Install fuel tube (line) at side of fuel rail.
Refer to Quick-Connect Fittings for procedures.
(12) Install air cleaner.
(13) Connect battery cable to battery.
(14) Start engine and check for leaks.
INSTALLATION - 8.0L
(1) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(2) Install injector(s) and injector clip(s) to fuel
rail.
NOTE: The fuel injector electrical connectors on all
10 injectors should be facing to the right (passen-
ger) side of the vehicle (Fig. 31).
(3) Position the fuel rail/fuel injector assembly to
the injector openings on the intake manifold.
(4) Guide each injector into the intake manifold.
Be careful not to tear the injector o-ring.
(5) Push therightfuel rail down until fuel injec-
tors have bottomed on injector shoulder. Push the
leftfuel rail down until fuel injectors have bottomed
on injector shoulder.
(6) Install the six fuel rail mounting bolts into the
lower half of intake manifold. Tighten bolts to 15
N´m (136 in. lbs.) torque.
(7) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 30). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector. The injector wir-
ing harness is numerically tagged.
(8) Install upper half of intake manifold. Refer to
Engines for procedures.
(9) Connect main fuel line at fuel rail. Refer to
Quick-Connect Fittings for procedures.
(10) Install ignition coil pack and bracket assem-
bly at intake manifold and right engine valve cover
(four bolts).(11) Install throttle body to intake manifold. Refer
to Throttle Body removal in this group.
(12) Install throttle body linkage to throttle body.
(13) Install air cleaner tube and housing.
(14) Install negative battery cable at battery.
(15) Start engine and check for leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.
A fuel tank check valve(s) is mounted into the top
of the fuel tank (or pump module). Refer to Emission
Control System for fuel tank check valve information.
An evaporation control system is connected to the
rollover valve(s) to reduce emissions of fuel vapors
into the atmosphere. When fuel evaporates from the
fuel tank, vapors pass through vent hoses or tubes to
a charcoal canister where they are temporarily held.
When the engine is running, the vapors are drawn
into the intake manifold. Certain models are also
equipped with a self-diagnosing system using a Leak
Detection Pump (LDP). Refer to Emission Control
System for additional information.
REMOVAL
WARNING: GASOLINE POWERED ENGINES: THE
FUEL SYSTEM IS UNDER A CONSTANT PRESSURE
EVEN WITH THE ENGINE OFF. BEFORE SERVICING
THE FUEL TANK, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO THE FUEL SYSTEM
PRESSURE RELEASE PROCEDURE BEFORE SER-
VICING THE FUEL TANK.
Two different procedures may be used to drain fuel
tank (lowering tank or using DRB scan tool). When
equipped with a diesel engine, the DRB scan tool
cannot be used (no electric fuel pump).
The quickest draining procedure involves lowering
the fuel tank.
Gasoline Powered Engines:As an alternative
procedure, the electric fuel pump may be activated
allowing tank to be drained at fuel rail connection.
Refer to DRB scan tool for fuel pump activation pro-
cedures. Before disconnecting fuel line at fuel rail,
release fuel pressure. Refer to the Fuel System Pres-
sure Release Procedure in this group for procedures.
14 - 18 FUEL DELIVERY - GASOLINEBR/BE
FUEL RAIL (Continued)

Attach end of special test hose tool number 6541,
6539, 6631 or 6923 at fuel rail disconnection (tool
number will depend on model and/or engine applica-
tion). Position opposite end of this hose tool to an
approved gasoline draining station. Activate fuel
pump and drain tank until empty.
If electric fuel pump is not operating, tank must be
lowered for fuel draining. Refer to following proce-
dures.
(1) Remove fuel tank filler tube cap.
(2) Perform Fuel System Pressure Release proce-
dure as described in this group.
(3) Gasoline Engines: Disconnect negative battery
cable at battery. Diesel Engines: Disconnect both neg-
ative battery cables at both batteries.
(4) Raise vehicle on hoist.
(5) Certain models are equipped with a separate
grounding wire (strap) connecting the fuel fill tube
assembly to the body. Disconnect wire by removing
screw.
(6) Open fuel fill door and remove screws mount-
ing fuel filler tube assembly to body. Do not discon-
nect rubber fuel fill or vent hoses from tank at this
time.
(7) Place a transmission jack under center of fuel
tank. Apply a slight amount of pressure to fuel tank
with transmission jack.
(8) Remove fuel tank mounting strap nuts from
mounting strap studs (Fig. 32). If equipped, remove
fuel tank shield bolts.
(9) Lower fuel tank only enough to allow access to
top of tank. The 2 tank fittings (where rubber fuel fill
and vent hose connections are made) must be posi-
tioned above tank level. Rotate tank slightly to allow
these fittings to be above tank level.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(10) While working over left rear tire/wheel, dis-
connect rubber fuel vent hose at fuel tank (Fig. 32)
(vent hose is the smallest of 2 hoses). Position fuel
siphoning/drain hose into this fitting at tank. Drain
fuel into an approved portable holding tank or a
properly labeled gasoline (or diesel fuel) safety con-
tainer.
(11) Disconnect rubber fuel fill hose at fuel tank
(Fig. 32).
(12)Gas Powered Engines:
(a) While working over left rear tire/wheel, dis-
connect wiring harness connector from electrical
connector at top of fuel pump module (Fig. 33) or
(Fig. 34).
(b) If equipped with 26 or 34 gallon fuel tank,
two EVAP lines are connected to the fuel tank
check valves. Disconnect EVAP line from check
valve at top of module (Fig. 33). Disconnect otherEVAP line from check valve near rear of tank (Fig.
33).
(c) If equipped with 35 gallon fuel tank, two
EVAP lines are connected to the fuel tank check
valves. Disconnect EVAP lines from check valves at
top-front and top-rear of fuel tank (Fig. 35).
(d) Disconnect fuel supply line at fuel filter/fuel
pressure regulator supply fitting (Fig. 33) or (Fig.
34). Refer to Quick-Connect Fittings for proce-
dures.
(13)Diesel Powered Engines:
(a) While working over left rear tire/wheel, dis-
connect wiring harness connector from electrical
connector at top of fuel tank module (Fig. 36).
(b) Disconnect fuel supply and fuel return lines
at the fuel tank module fittings (Fig. 36). Refer to
Quick-Connect Fittings for procedures.
(14) Gasoline Engines: If fuel pump module
removal is necessary, refer to Fuel Pump Module
Removal/Installation in this group. Diesel Engines: If
fuel tank module removal is necessary, refer to Fuel
Tank Module Removal/Installation in this group.
Fig. 32 Fuel Tank MountingÐTypical
1 - STRAP MOUNTING STUDS (AT FRAME)
2 - FUEL FILL HOSE
3 - FUEL VENT HOSE
4 - STRAP MOUNTING NUTS (2)
5 - FUEL TANK STRAPS (2)
6 - FUEL TANK
7 - CLAMPS
BR/BEFUEL DELIVERY - GASOLINE 14 - 19
FUEL TANK (Continued)

REMOVAL - 8.0L
The crankshaft position sensor is located on the
right-lower side of the cylinder block, forward of the
right engine mount, just above the oil pan rail (Fig.
27).
(1) Raise and support vehicle.
(2) Disconnect sensor pigtail harness from main
engine wiring harness.
(3) Remove sensor mounting bolt (Fig. 28).
(4) Cut plastic tie strap (Fig. 27) securing sensor
pigtail harness to side of engine block.
(5) Carefully pry sensor from cylinder block in a
rocking action with two small screwdrivers.
(6) Remove sensor from vehicle.
(7) Check condition of sensor o-ring (Fig. 29).
INSTALLATION
INSTALLATION - 5.9L
(1) Position crankshaft position sensor to engine.
(2) Install mounting bolts and tighten to 8 N´m (70
in. lbs.) torque.
(3) Connect main harness electrical connector to
sensor.
(4) Install air cleaner tube.
INSTALLATION - 8.0L
The crankshaft position sensor is located on the
right-lower side of the cylinder block, forward of the
right engine mount, just above the oil pan rail (Fig.
27).
(1) Apply a small amount of engine oil to sensor
o-ring (Fig. 29).
(2) Install sensor into cylinder block with a slight
rocking action. Do not twist sensor into position as
damage to o-ring may result.
Fig. 27 Crankshaft Position Sensor LocationÐ8.0L
V-10 Engine
1 - CRANKSHAFT POSITION SENSOR
2 - HOLE
3 - OIL FILTER
4 - PLASTIC TIE STRAP
5 - PIGTAIL HARNESS
Fig. 28 Sensor Removal/InstallationÐ8.0L V-10
Engine
1 - CRANKSHAFT POSITION SENSOR
2 - MOUNTING BOLT
3 - SENSOR POSITIONED FLUSH TO CYLINDER BLOCK
Fig. 29 Sensor O-RingÐ8.0L V-10 Engine
1 - CRANKSHAFT POSITION SENSOR O-RING
2 - ELECTRICAL CONNECTOR
3 - PIGTAIL HARNESS
BR/BEFUEL INJECTION - GASOLINE 14 - 39
CRANKSHAFT POSITION SENSOR (Continued)

To make the IAC go in the opposite direction, the
PCM just reverses polarity on both windings. If only
1 wire is open, the IAC can only be moved 1 step
(increment) in either direction. To keep the IAC
motor in position when no movement is needed, the
PCM will energize both windings at the same time.
This locks the IAC motor in place.
In the IAC motor system, the PCM will count
every step that the motor is moved. This allows the
PCM to determine the motor pintle position. If the
memory is cleared, the PCM no longer knows the
position of the pintle. So at the first key ON, the
PCM drives the IAC motor closed, regardless of
where it was before. This zeros the counter. From
this point the PCM will back out the IAC motor and
keep track of its position again.
When engine rpm is above idle speed, the IAC is
used for the following:
²Off-idle dashpot (throttle blade will close quickly
but idle speed will not stop quickly)
²Deceleration air flow control
²A/C compressor load control (also opens the pas-
sage slightly before the compressor is engaged so
that the engine rpm does not dip down when the
compressor engages)
²Power steering load control
The PCM can control polarity of the circuit to con-
trol direction of the stepper motor.
IAC Stepper Motor Program:The PCM is also
equipped with a memory program that records the
number of steps the IAC stepper motor most recently
advanced to during a certain set of parameters. For
example: The PCM was attempting to maintain a
1000 rpm target during a cold start-up cycle. The last
recorded number of steps for that may have been
125. That value would be recorded in the memory
cell so that the next time the PCM recognizes the
identical conditions, the PCM recalls that 125 steps
were required to maintain the target. This program
allows for greater customer satisfaction due to
greater control of engine idle.
Another function of the memory program, which
occurs when the power steering switch (if equipped),
or the A/C request circuit, requires that the IAC step-
per motor control engine rpm, is the recording of the
last targeted steps into the memory cell. The PCM
can anticipate A/C compressor loads. This is accom-
plished by delaying compressor operation for approx-
imately 0.5 seconds until the PCM moves the IAC
stepper motor to the recorded steps that were loaded
into the memory cell. Using this program helps elim-
inate idle-quality changes as loads change. Finally,
the PCM incorporates a9No-Load9engine speed lim-
iter of approximately 1800 - 2000 rpm, when it rec-
ognizes that the TPS is indicating an idle signal and
IAC motor cannot maintain engine idle.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 IAC motor through the PCM.
REMOVAL
REMOVAL - 5.9L
The IAC motor is located on the back of the throt-
tle body (Fig. 31).
(1) Remove air cleaner assembly.
(2) Disconnect electrical connector from IAC motor.
(3) Remove two mounting bolts (screws) (Fig. 31).
(4) Remove IAC motor from throttle body.
REMOVAL - 8.0L
The IAC motor is located on the back of the throt-
tle body (Fig. 32).
(1) Remove the air cleaner cover.
(2) Remove the 4 air cleaner housing mounting
nuts and remove housing from throttle body.
(3) Disconnect electrical connector from IAC motor.
(4) Remove two mounting bolts (screw).
(5) Remove IAC motor from throttle body.
Fig. 31 Mounting Bolts (Screws)ÐIAC MotorÐ5.9L
Engines
1 - MOUNTING SCREWS
2 - IDLE SPEED MOTOR
BR/BEFUEL INJECTION - GASOLINE 14 - 41
IDLE AIR CONTROL MOTOR (Continued)

INSTALLATION
INSTALLATION - 5.9L
The throttle shaft end of the throttle body slides
into a socket in the TPS (Fig. 48). 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 intake tube.
INSTALLATION - 8.0L
The throttle shaft end of the throttle body slides
into a socket in the TPS (Fig. 49). 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.
Fig. 46 TPS Mounting BoltsÐ5.9L Engines
1 - THROTTLE POSITION SENSOR
2 - MOUNTING SCREWS
Fig. 47 TPS Mounting BoltsÐ8.0L Engine
1 - MOUNTING BOLTS (2)
2 - IDLE AIR CONTROL MOTOR
3 - THROTTLE POSITION SENSOR
4 - THROTTLE BODY
Fig. 48 InstallationÐ5.9L EnginesÐTypical
1 - THROTTLE BODY
2 - THROTTLE POSITION SENSOR
3 - THROTTLE SHAFT
4 - SOCKET LOCATING TANGS
Fig. 49 InstallationÐTypical Mounting
1 - THROTTLE BODY
2 - THROTTLE POSITION SENSOR
3 - THROTTLE SHAFT
4 - SOCKET LOCATING TANGS
BR/BEFUEL INJECTION - GASOLINE 14 - 51
THROTTLE POSITION SENSOR (Continued)

(c) Check condition of o-ring.
(d) Inspect the 2 WIF sensor probes. Carefully
clean contaminants from sensor probes with a cloth
if necessary. Replace sensor if probes are covered
with contaminants and will not clean up.
(7)Fuel Heater Element Replacement:The
heater element is located in the fuel filter housing
(Fig. 15).
(a) Remove fuel filter. See previous steps.
(b) Disconnect electrical connector from fuel tem-
perature sensor housing at side of fuel filter hous-
ing (Fig. 17).
(c) Remove 2 temperature sensor housing
mounting screws and carefully remove sensor
housing from fuel filter housing.
(d) Pry round wiring connector from fuel filter
housing and heater element. This connector passes
through the fuel filter housing and is plugged
directly into the heater element.
(e) Unlock heater element fingers and pry heater
element from filter housing.
(8)Drain Valve Replacement:The drain valve is
located on the side of the fuel filter housing (Fig. 15).
(a) Disconnect drain hose (Fig. 14) at bottom of
drain valve.
(b) Remove 4 drain valve mounting screws.
(c) Remove drain valve from filter housing.
(d) Remove 2 drain valve o-rings from filter
housing.
INSTALLATION
Refer to maintenance schedules in this manual for
recommended fuel filter replacement intervals.
(1) Thoroughly clean inside of filter housing, filter
cap and all related components.
(2)Fuel Filter:
(a) Fill fuel filter housing with clean diesel fuel.
If filter housing (canister) is not filled with
clean diesel fuel before installation, manual
air bleeding of fuel system may be necessary
(temporary rough engine running may occur).
If necessary, refer to Air Bleed Procedures.
(b) Snap new filter into locking fingers on cap.
Hole in filter should face downward.
(c) Install new o-ring to cap.
(d) Apply a light film of clean diesel oil to cap
o-ring seal.
(e) Load filter and cap into housing.
(f) Tighten cap to 25 ft. lbs. torque. Do not over-
tighten cap.
(3)Water-In-Fuel (WIF) Sensor:
(a) Install new o-ring seal to WIF sensor.
(b) Apply a light film of clean diesel oil to o-ring
seal.
(c) Install sensor into housing.
Fig. 16 Water-In-Fuel Sensor
1 - WATER-IN-FUEL (WIF) SENSOR
2 - FUEL FILTER/WATER SEPARATOR
3 - WIF SENSOR CONNECTOR
Fig. 17 Fuel Heater/Filter/Water Separator Location
1 - FUEL HEATER AND TEMP. SENSOR
2 - FUEL FILTER/WATER SEPARATOR
3 - FUEL HEATER ELECTRICAL CONNECTOR
BR/BEFUEL DELIVERY - DIESEL 14 - 65
FUEL FILTER / WATER SEPARATOR (Continued)