wheel DODGE RAM 2002 Service Repair Manual

(22) Inspect for pinched or leaking fuel tubes.
Inspect for pinched, cracked or leaking fuel hoses.
(23) Inspect for exhaust system restrictions such
as pinched exhaust pipes, collapsed muffler or
plugged catalytic convertor.
(24) If equipped with automatic transmission, ver-
ify that electrical harness is firmly connected to park/
neutral switch. Refer to 21, Automatic Transmission.(25) Verify electrical harness is firmly connected to
rear wheel speed sensor. Verify rear wheel speed sen-
sor is firmly attached to rear axle with proper air
gap. Refer to 5, Brakes for information.
(26) If equipped with 4±wheel antilock brake sys-
tem, verify electrical harness is firmly connected to
each front wheel speed sensor. Verify both front
wheel speed sensors are firmly attached. Refer to 5,
Brakes for information.
(27) Verify that fuel pump/gauge sender unit wire
connector is firmly connected to harness connector.
(28) Inspect fuel hoses at fuel pump/gauge sender
unit for cracks or leaks.
Fig. 7 Rubber L-Shaped FittingÐMAP Sensor-to-
Throttle BodyÐ5.9L Engines
1 - MAP SENSOR
2 - RUBBER FITTING
3 - IDLE AIR PASSAGE
Fig. 8 Engine Coolant Temperature
1 - GENERATOR
2 - A/C COMPRESSOR
3 - ENGINE COOLANT TEMPERATURE SENSOR
4 - ELEC. CONN.
Fig. 9 Left/Right Oxygen SensorsÐHDC Engines
1 - DUAL OXYGEN SENSORS
2 - TOP OF TRANSMISSION
Fig. 10 Pre-Catalyst/Post-Catalyst Sensors
1 - POST CATALYST OXYGEN SENSOR (1/3)
2 - PRE-CATALYST OXYGEN SENSOR (1/2)
BR/BEFUEL INJECTION - GASOLINE 14 - 31
FUEL INJECTION - GASOLINE (Continued)

(29) Inspect transmission torque convertor housing
(automatic transmission) or clutch housing (manual
transmission) for damage to timing ring on drive
plate/flywheel.
(30) Verify that battery cable and solenoid feed
wire connections to the starter solenoid are tight and
clean. Inspect for chaffed wires or wires rubbing up
against other components.
VISUAL INSPECTIONÐ8.0L ENGINE
A visual inspection for loose, disconnected or incor-
rectly routed wires and hoses should be made. This
should be done before attempting to diagnose or ser-
vice the fuel injection system. A visual check will
help spot these faults and save unnecessary test and
diagnostic time. A thorough visual inspection will
include the following checks:
(1) Verify that the three 32±way electrical connec-
tors are fully inserted into the connector of the pow-
ertrain control module (PCM) (Fig. 12).
(2) Inspect the battery cable connections. Be sure
that they are clean and tight.
(3) Inspect fuel pump relay and air conditioning
compressor clutch relay (if equipped). Inspect the
ASD relay connections. Inspect starter motor relay
connections. Inspect relays for signs of physical dam-
age and corrosion. The relays are located in the
Power Distribution Center (PDC) (Fig. 13). Refer to
label on PDC cover for relay location.
(4) Inspect ignition coil pack primary connections.
Verify that secondary cables are firmly connected to
coils (Fig. 14).
(5) Be sure that spark plug cables are firmly con-
nected and the spark plugs are in their correct firing
order. Be sure that camshaft position sensor wire
connector is firmly connected to harness connector.
Inspect spark plug condition. Refer to 8, Ignition.Connect vehicle to an oscilloscope and inspect spark
events for fouled or damaged spark plugs or cables.
(6) Verify that generator output wire, generator
connector and ground wire are firmly connected to
the generator.
(7) Inspect the system body grounds for loose or
dirty connections. Refer to 8, Wiring for ground loca-
tions.
(8) Verify crankcase ventilation (CCV) operation.
Refer to 25, Emission Control System for additional
information.
(9) Inspect fuel tube quick-connect fitting-to-fuel
rail connections.
(10) Verify that hose connections to all ports of
vacuum fittings on intake manifold are tight and not
leaking.
Fig. 11 Oxygen SensorsFig. 12 Powertrain Control Module (PCM)
1 - PCM MOUNTING BOLTS (3)
2 - POWERTRAIN CONTROL MODULE (PCM)
3 - (3) 32±WAY CONNECTORS
Fig. 13 Power Distribution Center (PDC)
1 - POWER DISTRIBUTION CENTER (PDC)
14 - 32 FUEL INJECTION - GASOLINEBR/BE
FUEL INJECTION - GASOLINE (Continued)

(20) Raise and support the vehicle.
(21) Verify that all oxygen sensor wire connectors
are firmly connected to the sensors. Inspect sensors
and connectors for damage (Fig. 18), (Fig. 19) or (Fig.
20).
(22) Inspect for pinched or leaking fuel tubes.
Inspect for pinched, cracked or leaking fuel hoses.
(23) Inspect for exhaust system restrictions such
as pinched exhaust pipes, collapsed muffler or
plugged catalytic convertor.
(24) If equipped with automatic transmission, ver-
ify that electrical harness is firmly connected to park/
neutral switch. Refer to 21, Automatic Transmission.
(25) Verify electrical harness is firmly connected to
rear wheel speed sensor. Verify rear wheel speed sen-
sor is firmly attached to rear axle with proper air
gap. Refer to 5, Brakes for information.
(26) If equipped with 4±wheel antilock brake sys-
tem, verify electrical harness is firmly connected to
each front wheel speed sensor. Verify both front
wheel speed sensors are firmly attached. Refer to 5,
Brakes for information.
(27) Verify that fuel pump/gauge sender unit wire
connector is firmly connected to harness connector.
(28) Inspect fuel hoses at fuel pump/gauge sender
unit for cracks or leaks.
(29) Inspect transmission torque convertor housing
(automatic transmission) or clutch housing (manual
transmission) for damage to timing ring on drive
plate/flywheel.
(30) Verify that battery cable and solenoid feed
wire connections to the starter solenoid are tight and
clean. Inspect for chaffed wires or wires rubbing up
against other components.
Fig. 18 Upstream/Downstream Oxygen Sensors
1 - DOWN STREAM OXYGEN SENSOR (1/2)
2 - UP STREAM OXYGEN SENSOR (1/1)
Fig. 19 Left/Right
1 - DUAL OXYGEN SENSORS
2 - TOP OF TRANSMISSION
Fig. 20 Pre-Catalyst/Post Catalyst Oxygen Sensors
1 - POST CATALYST OXYGEN SENSOR (1/3)
2 - PRE-CATALYST OXYGEN SENSOR (1/2)
14 - 34 FUEL INJECTION - GASOLINEBR/BE
FUEL INJECTION - GASOLINE (Continued)

INSTALLATION
(1) Position pedal/bracket assembly over pivot pin
(Fig. 22) .
(2) Install two new pivots/bushings. Using large
pliers, press both bushings together until they bot-
tom on sides of pedal/bracket assembly. Bushing
retaining ears will snap into position when properly
installed.
(3) 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. 21) . Align
index slot on plastic cable retainer to this index tab.
CRANKSHAFT POSITION
SENSOR
DESCRIPTION
DESCRIPTION - 5.9L
The Crankshaft Position (CKP) sensor is located
near the outer edge of the flywheel (starter ringear).
DESCRIPTION - 8.0L
The Crankshaft Position (CKP) 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. 23).
OPERATION
OPERATION - 5.9L
Engine speed and crankshaft position are provided
through the CKP sensor. The sensor generates pulses
that are the input sent to the Powertrain Control
Module (PCM). The PCM interprets the sensor input
to determine the crankshaft position. The PCM then
uses this position, along with other inputs, to deter-
mine injector sequence and ignition timing.
The sensor is a hall effect device combined with an
internal magnet. It is also sensitive to steel within a
certain distance from it.
On 5.9L V-8 engines, the flywheel/drive plate has 8
single notches, spaced every 45 degrees, at its outer
edge (Fig. 24).
The notches cause a pulse to be generated when
they pass under the sensor. The pulses are the input
to the PCM. For each engine revolution, there are 8
pulses generated on V-8 engines.
The engine will not operate if the PCM does not
receive a CKP sensor input.
Fig. 22 Accelerator PedalÐRemoval or Installation
1 - PEDAL MOUNTING BRACKET
2 - PIVOTS/BUSHINGS
3 - PEDAL/BRACKET
4 - PIVOT PIN
Fig. 23 CKP Sensor LocationÐ8.0L V-10 Engine
1 - CRANKSHAFT POSITION SENSOR
2 - HOLE
3 - OIL FILTER
4 - PLASTIC TIE STRAP
5 - PIGTAIL HARNESS
BR/BEFUEL INJECTION - GASOLINE 14 - 37
ACCELERATOR PEDAL (Continued)

OPERATION - 8.0L
The Crankshaft Position (CKP) sensor detects
notches machined into the middle of the crankshaft
(Fig. 25).There are five sets of notches. Each set contains
two notches. Basic ignition timing is determined by
the position of the last notch in each set of notches.
Once the Powertrain Control Module (PCM) senses
the last notch, it will determine crankshaft position
(which piston will next be at Top Dead Center). An
input from the camshaft position sensor is also
needed. It may take the module up to one complete
engine revolution to determine crankshaft position
during engine cranking.
The PCM uses the signal from the camshaft posi-
tion sensor to determine fuel injector sequence. Once
crankshaft position has been determined, the PCM
begins energizing a ground circuit to each fuel injec-
tor to provide injector operation.
REMOVAL
REMOVAL - 5.9L
The sensor is bolted to the top of the cylinder block
near the rear of right cylinder head (Fig. 26).
(1) Remove the air cleaner intake tube.
(2) Disconnect crankshaft position sensor pigtail
harness from main wiring harness.
(3) Remove two sensor (recessed hex head) mount-
ing bolts (Fig. 26).
(4) Remove sensor from engine.
Fig. 24 CKP Sensor OperationÐ5.9L Engine
1 - CRANKSHAFT POSITION SENSOR
2 - NOTCHES
3 - FLYWHEEL
Fig. 25 CKP Sensor OperationÐ8.0L V-10 Engine
1 - CRANKSHAFT NOTCHES
2 - CRANKSHAFT
3 - CRANKSHAFT POSITION SENSOR
Fig. 26 Crankshaft Position Sensor
1 - GROMMET
2 - MOUNTING BOLTS (2)
3 - CRANKSHAFT POSITION SENSOR
4 - RIGHT EXHAUST MANIFOLD
5 - TRANSMISSION BELL HOUSING
14 - 38 FUEL INJECTION - GASOLINEBR/BE
CRANKSHAFT POSITION SENSOR (Continued)

(10) The engine can be rotated with a barring tool
such as Snap-On No. SP371, MTE No. 3377371
(Cummins Tool Division), or an equivalent. The open-
ing for barring tool is located in rear flange of engine
on exhaust manifold side (Fig. 35). Remove rubber
access plug covering this opening.
(11) Insert barring tool into flywheel housing open-
ing (Fig. 35).(12) Rotate engine until keyway is at 12 o'clock
position (Fig. 36).
Fig. 36 Placing Keyway at 12 O'clock Position
1 - KEYWAY AT 12 O'CLOCK POSITION
2 - PUMP GEAR
Fig. 37 Separating Injection Pump Gear from Pump
Shaft
1 - T-BAR PULLER
Fig. 38 Rear/Lower Pump Bracket and Mounting
Bolts
1 - FUEL INJECTION PUMP
2 - BOLTS (2)
3 - REAR/LOWER BRACKET
Fig. 39 Injection Pump Mounting Nuts
1 - PUMP MOUNTING NUTS (4)
14 - 74 FUEL DELIVERY - DIESELBR/BE
FUEL INJECTION PUMP (Continued)

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER STEERING SYSTEM
STEERING NOISE
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.
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONAL HISS OR
WHISTLE1. Steering intermediate shaft to dash panel
seal.1. Check and repair seal at dash
panel.
2. Noisy valve in power steering gear. 2. Repair steering gear.
RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension
components.2. Inspect and repair suspension.
3. Loose or damaged steering linkage. 3. Inspect and repair steering
linkage.
4. Internal gear noise. 4. Repair steering gear.
5. Pressure hose in contact with other
components.5. Reposition hose.
6. Loose or damaged intermediate shaft or
column.6. Inspect and repair or replace.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with other
components.2. Reposition hose.
3. Internal pump noise. 3. Replace pump.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on hose
fitting.2. Replace o-ring.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
5. Reservoir cap not installed correctly. 5. Install reservoir cap correctly.
SCRUBBING OR
KNOCKING1. Wrong tire size. 1. Verify tire size.
2. Wrong gear. 2. Verify gear.
19 - 2 STEERINGBR/BE
STEERING (Continued)

BINDING AND STICKING
CONDITION POSSIBLE CAUSE CORRECTION
DIFFICULT TO TURN WHEEL
STICKS OR BINDS1. Low fluid level. 1. Fill to proper level.
2. Tire pressure. 2. Adjust tire pressure.
3. Steering components (ball
joints/tie rod ends).3. Lube, inspect and repair as
necessary.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if
necessary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn or out of
adjustment.7. Repair or replace gear.
INSUFFICIENT ASST. OR POOR RETURN TO CENTER
CONDITION POSSIBLE CAUSE CORRECTION
HARD TURNING OR MOMENTARY
INCREASE IN TURNING EFFORT1. Tire pressure. 1. Adjust tire pressure.
2. Low fluid level. 2. Fill to proper level.
3. Loose belt. 3. Adjust or replace.
4. Lack of lubrication. 4. Inspect and lubricate steering and
suspension compnents.
5. Low pump pressure. 5. Pressure test and repair as
necessary.
6. Internal gear leak. 6. Pressure and flow test, and repair
as necessary.
STEERING WHEEL DOES NOT
WANT TO RETURN TO CENTER
POSITION1. Tire pressure. 1. Adjust tire pressure.
2. Wheel alignment. 2. Align front end.
3. Lack of lubrication. 3. Inspect and lubricate steering and
suspension compnents.
4. High friction in steering gear. 4. Test and adjust gear as
necessary.
BR/BESTEERING 19 - 3
STEERING (Continued)

LOOSE STEERING AND VEHICLE LEAD
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE PLAY IN STEERING
WHEEL1. Worn or loose suspension or
steering components.1. Inspect and repair as necessary.
2. Worn or loose wheel bearings. 2. Inspect and repair or adjust
bearings.
3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Adjust gear to specification.
5. Worn or loose steering coupler. 5. Inspect and replace as
necessary.
VEHICLE PULLS OR LEADS TO
ONE SIDE.1. Tire Pressure. 1. Adjust tire pressure.
2. Radial tire lead. 2. Rotate tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align front end.
DIAGNOSIS AND TESTING - POWER STEERING
FLOW AND PRESSURE
The following procedure is used to test the opera-
tion of the power steering system on the vehicle. This
test will provide the flow rate of the power steering
pump along with the maximum relief pressure. Per-
form 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 function-
ing properly. The following pressure and flow test is
performed using Power Steering Analyzer Tool kit
6815 (Fig. 2) and Adapter Kit 6893.
POWER STEERING ANALYZER INSTALLATION
WITHOUT HYDRAULIC BOOSTER
(1) Remove the high pressure hose from the power
steering pump.
(2) Connect Tube 6844 into the pump hose fitting.
(3) Connect pressure gauge hose from the Power
Steering Analyzer to Tube 6844.
(4) Connect Adapter 6826 to Power Steering Ana-
lyzer test valve end.
(5) Connect the power steering hose from the
steering gear to Adapter 6826.
WITH HYDRAULIC BOOSTER
(1) Remove high pressure hose which goes to the
steering gear from the tube coming out of the booster.
(2) Connect Adapter 6826 to the Power Steering
Analyzer pressure gauge hose.
(3) Connect pressure gauge hose to the tube com-
ing out of the booster.
(4) Connect Tube 6844 to the steering gear hose
and Power Steering Analyzer test valve end.
FLOW AND PRESSURE TEST
(1) Check belt condition and tension.
(2) Open the test valve completely.
(3) 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.
(4) Check fluid level, add fluid as necessary. Start
engine again and let idle.
(5) Gauge should read below 1034 kPa (150 psi), if
above, inspect the hoses for restrictions and repair as
Fig. 2 Pressure Test Gauge
1 - GAUGE HOSE
2 - TUBE
3 - ADAPTER FITTINGS
4 - ANALYZER
19 - 4 STEERINGBR/BE
STEERING (Continued)

necessary. The initial pressure reading should be in
the range of 345-552 kPa (50-80 psi).
(6) 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.
(7) 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.
²Pressures above specifications but not within
345 kPa (50 psi) of each other, replace pump.
²Pressures within 345 kPa (50 psi) of each other
but below specifications, replace pump.
(8) 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 the readings to
the pump specifications chart. If pressures readings
are not within 50 psi of each other, the gear is leak-
ing internally and must be repaired.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
ENGINERELIEF PRESSURE
(P.S.I.)FLOW
(G.P.M.) at
1500 RPM
3.9L 1450 to 1550 2.7 to 3.1
5.2L 1450 to 1550 2.7 to 3.1
5.9L 1450 to 1550 2.7 to 3.1
8.0L 1450 to 1550 2.7 to 3.1
5.9L
Diesel1450 to 1550 3.1 to 3.5
All With
Hydraulic
Booster1450 to 1550 3.1 to 3.5
NOTE: After preforming test and removing Power
Steering Analyzer, check power steering fluid level.
BR/BESTEERING 19 - 5
STEERING (Continued)