coolant temperature DODGE RAM 2002 Service Service Manual

8W-02 COMPONENT INDEX
Component Page
4WD Switch.......................... 8W-31
A/C Compressor Clutch Relay............ 8W-42
A/C Compressor Clutch................. 8W-42
A/C- Heater Control.................... 8W-42
A/C Heater Temperature Select........... 8W-42
A/C High Pressure Switch............... 8W-42
A/C Low Pressure Switch................ 8W-42
Accelerator Pedal Position Sensor......... 8W-30
Aftermarket Center High Mounted Stop
Lamp............................. 8W-51
Aftermarket Trailer Tow Connector........ 8W-54
Airbag Control Module.................. 8W-43
Ambient Temperature Sensor............ 8W-49
Ash Receiver Lamp.................... 8W-44
Automatic Day/Night Mirror............. 8W-49
Automatic Shut Down Relay............. 8W-30
Auxiliary Battery...................... 8W-20
Back-Up Lamp Switch.................. 8W-51
Back-Up Lamp........................ 8W-51
Battery Temperature Sensor............. 8W-30
Battery............................. 8W-20
Blend Door Actuator................... 8W-42
Blower Motor Relay.................... 8W-42
Blower Motor Resistor Block............. 8W-42
Blower Motor......................... 8W-42
Brake Lamp Switch.................... 8W-51
Brake Pressure Switch............... 8W-34, 35
Bypass Jumper....................... 8W-21
Camshaft Position Sensor............... 8W-30
Capacitor......................... 8W-10, 30
Cargo Lamps........................ 8W-44
Center High Mounted Stop Lamps........ 8W-51
Center Identification Lamp.............. 8W-50
Central Timer Module.................. 8W-45
Cigar Lighter......................... 8W-41
Circuit Breakers...................... 8W-12
Clockspring.................. 8W-33, 41, 43, 47
Clutch Pedal Position Switch............. 8W-21
Combination Flasher................... 8W-52
Controller Antilock Brake............ 8W-34, 35
Crankshaft Position Sensor.............. 8W-30
Cummins Bus........................ 8W-18
Cup Holder Lamp..................... 8W-44
Data Link Connector................... 8W-18
Daytime Running Lamp Module.......... 8W-50
Dome Lamp.......................... 8W-44
Driver Airbag......................... 8W-43
Driver Cylinder Lock Switch............. 8W-39
Driver Door Ajar Switch................ 8W-45
Driver Door Lock Motor................. 8W-61
Driver Door Window/Lock Switch...... 8W-60, 61
Driver Heated Seat Cushion............. 8W-63Component Page
Driver Heated Seat Switch.............. 8W-63
Driver Lumbar Motor.................. 8W-63
Driver Power Seat Front Vertical Motor.... 8W-63
Driver Power Seat Horizontal Motor....... 8W-63
Driver Power Seat Rear Vertical Motor..... 8W-63
Driver Power Seat Switch............... 8W-63
Driver Power Window Motor............. 8W-60
Electric Brake Provision................ 8W-54
Engine Control Module................. 8W-30
Engine Coolant Temperature Sensor....... 8W-30
Engine Oil Pressure Sensor.............. 8W-30
Engine Starter Motor Relay.............. 8W-21
Engine Starter Motor................... 8W-21
EVAP/Purge Solenoid................... 8W-30
Fender Lamp......................... 8W-51
Fog Lamp Relay....................... 8W-50
Fog Lamp............................ 8W-50
Fuel Heater Relay..................... 8W-30
Fuel Heater........................ 8W-30-36
Fuel Injection Pump................... 8W-30
Fuel Injectors......................... 8W-30
Fuel Pump Module.................... 8W-30
Fuel Pump Relay...................... 8W-30
Fuel Tank Module..................... 8W-30
Fuel Transfer Pump.................... 8W-30
Fuses (JB)........................... 8W-12
Fuses (PDC).......................... 8W-10
Fusible Link....................... 8W-20, 30
Grounds............................. 8W-15
Generator............................ 8W-20
Glove Box Lamp And Switch............. 8W-44
Headlamp Beam Select Switch........... 8W-50
Headlamp Switch...................... 8W-50
Headlamp........................... 8W-50
Heated Mirror Relay................... 8W-62
Heated Mirror Switch.................. 8W-62
Heated Seat Relay..................... 8W-12
High Note Horn....................... 8W-41
Horn Relay.......................... 8W-41
Horn Switch.......................... 8W-41
Idle Air Control Motor.................. 8W-30
Ignition Coils......................... 8W-30
Ignition Switch....................... 8W-10
Instrument Cluster.................... 8W-40
Intake Air Heater Relays................ 8W-30
Intake Air Heater..................... 8W-30
Intake Air Temperature Sensor........... 8W-30
Intermittent Wiper Switch............... 8W-53
Joint Connectors....... 8W-10, 12, 15, 30, 34, 35,
40, 44, 45, 51, 53, 54, 70
Junction Block........................ 8W-12
Leak Detection Pump.................. 8W-30
BR/BE8W-02 COMPONENT INDEX 8W - 02 - 1

8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch Relay.... 8W-30-14, 38, 39
A/C High Pressure Switch.......... 8W-30-14, 39
A/C Low Pressure Switch.......... 8W-30-14, 39
A/C-Heater Control............... 8W-30-14, 39
Accelerator Pedal Position Sensor....... 8W-30-30
Airbag Control Module............ 8W-30-15, 40
Automatic Shut Down Relay..... 8W-30-3, 17, 18,
19, 22, 23, 24, 25, 26, 27, 28
Battery........................... 8W-30-35
Battery Temperature Sensor............ 8W-30-4
Brake Lamp Switch.............. 8W-30-8, 7, 37
Camshaft Position Sensor........... 8W-30-5, 32
Capacitor......................... 8W-30-28
Central Timer Module............. 8W-30-15, 40
Clockspring...................... 8W-30-7, 34
Controller Antilock Brake.... 8W-30-13, 15, 38, 40
Crankshaft Position Sensor............ 8W-30-13
Cummins Bus...................... 8W-30-29
Data Link Connector...... 8W-30-2, 15, 16, 40, 41
Daytime Running Lamp Module........ 8W-30-38
Engine Control Module . . 8W-30-3, 7, 29, 30, 31, 32,
33, 34, 35, 36, 37, 38, 39, 40, 41
Engine Coolant Temperature Sensor . . . 8W-30-9, 34
Engine Oil Pressure Sensor......... 8W-30-13, 33
EVAP/Purge Solenoid................ 8W-30-13
Fuel Heater........................ 8W-30-36
Fuel Heater Relay................... 8W-30-36
Fuel Injection Pump.............. 8W-30-31, 37
Fuel Injector No. 1............... 8W-30-23, 26
Fuel Injector No. 2............... 8W-30-24, 27
Fuel Injector No. 3............... 8W-30-23, 26
Fuel Injector No. 4............... 8W-30-24, 27
Fuel Injector No. 5............... 8W-30-23, 26
Fuel Injector No. 6............... 8W-30-24, 27
Fuel Injector No. 7............... 8W-30-23, 26
Fuel Injector No. 8............... 8W-30-24, 27
Fuel Injector No. 9.................. 8W-30-26
Fuel Injector No. 10................. 8W-30-27
Fuel Pump Module.................. 8W-30-12
Fuel Pump Relay......... 8W-30-3, 11, 12, 31, 37
Fuel Tank Module................... 8W-30-42
Fuel Transfer Pump................. 8W-30-34
Fuse 3 (PDC)............... 8W-30-2, 11, 29, 37
Fuse 6 (PDC)....................... 8W-30-3
Fuse 7 (PDC)...................... 8W-30-36
Fuse 9 (JB)................. 8W-30-2, 3, 11, 36
Fuse 11 (JB)................. 8W-30-13, 36, 39
Fuse 12 (JB).................... 8W-30-16, 41
Fuse K (PDC)........... 8W-30-17, 18, 19, 20, 22
Fusible Link....................... 8W-30-35
G100............................. 8W-30-12
G102.......................... 8W-30-36, 37Component Page
G105..................... 8W-30-2, 16, 20, 21
G107.......................... 8W-30-34, 36
G113 .......................... 8W-30-14, 34
G200.......................... 8W-30-16, 37
Generator...................... 8W-30-13, 38
Idle Air Control Motor................ 8W-30-9
Ignition Coil....................... 8W-30-25
Ignition Coil 4 Pack................. 8W-30-28
Ignition Coil 6 Pack................. 8W-30-28
Instrument Cluster............ 8W-30-15, 34, 40
Intake Air Heater................... 8W-30-35
Intake Air Heater Relay No. 1......... 8W-30-35
Intake Air Heater Relay No. 2......... 8W-30-35
Intake Air Temperature Sensor...... 8W-30-10, 32
Joint Connector No. 1....... 8W-30-4, 7, 8, 12, 36,
37, 38, 42
Joint Connector No. 2 . . . 8W-30-2, 3, 11, 17, 18, 19,
22, 23, 24, 25, 26, 27, 28, 29, 35, 37
Joint Connector No. 5............. 8W-30-16, 41
Joint Connector No. 7............. 8W-30-15, 40
Junction Block . . . 8W-30-2, 3, 11, 13, 16, 36, 39, 41
Leak Detection Pump................. 8W-30-8
Left Speed Control Switch............. 8W-30-7
Manifold Absolute Pressure Sensor . . . 8W-30-10, 33
Output Speed Sensor................. 8W-30-5
Overdrive Switch.................... 8W-30-6
Overhead Console................ 8W-30-15, 40
Oxygen Sensor 1/1 Left Bank Up.... 8W-30-18, 20,
21, 22
Oxygen Sensor 1/1 Upstream.......... 8W-30-17
Oxygen Sensor 1/2 Downstream........ 8W-30-17
Oxygen Sensor 1/2 Left Bank Down..... 8W-30-20
Oxygen Sensor 1/2 Pre- Catalyst........ 8W-30-21
Oxygen Sensor 1/3 Post- Catalyst....... 8W-30-21
Oxygen Sensor 2/1 Right Bank Up . . . 8W-30-18, 20,
21, 22
Oxygen Sensor 2/2 Right Bank Down.... 8W-30-20
Oxygen Sensor Downstream Relay . . . 8W-30-19, 21
Park/Neutral Position Switch....... 8W-30-13, 38
Power Distribution Center . . 8W-30-2, 3, 11, 17, 18,
19, 22, 23, 24, 25, 26, 27, 28, 29, 36, 37
Powertrain Control Module . . 8W-30-2, 3, 4, 5, 6, 7,
10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22,
23, 24, 25, 26, 27, 28, 36, 37, 38, 39, 40, 41, 42
PTO Switch..................... 8W-30-14, 34
Radio.......................... 8W-30-15, 40
Right Speed Control Switch............ 8W-30-7
Speed Control Servo.................. 8W-30-5
Throttle Position Sensor.............. 8W-30-14
Transmission Control Relay............ 8W-30-5
Transmission Solenoid Assembly . . . 8W-30-6, 14, 39
Water In Fuel Sensor................ 8W-30-34
BR/BE8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1

Component Page
Clutch Pedal Position Switch (M/T)..... 8W-80-35
Controller Antilock Brake C1.......... 8W-80-35
Controller Antilock Brake C2 (ABS)..... 8W-80-35
Crankshaft Position Sensor (Gas 8.0L) . . . 8W-80-36
Crankshaft Position Sensor
(Gas Except 8.0L)................. 8W-80-36
Cummins Bus (Diesel)............... 8W-80-36
Cup Holder Lamp................... 8W-80-36
Data Link Connector................. 8W-80-36
Daytime Running Lamp Module........ 8W-80-37
Dome Lamp....................... 8W-80-37
Driver Airbag...................... 8W-80-37
Driver Cylinder Lock Switch........... 8W-80-37
Driver Door Ajar Switch (Base)......... 8W-80-38
Driver Door Ajar Switch (Premium)..... 8W-80-38
Driver Door Lock Motor.............. 8W-80-38
Driver Door Window/Lock Switch....... 8W-80-38
Driver Heated Seat Cushion........... 8W-80-38
Driver Heated Seat Switch............ 8W-80-39
Driver Lumbar Motor................ 8W-80-39
Driver Power Seat Front Vertical Motor
(Club Cab)....................... 8W-80-39
Driver Power Seat Front Vertical Motor
(Standard Cab)................... 8W-80-39
Driver Power Seat Horizontal Motor
(Club Cab)....................... 8W-80-39
Driver Power Seat Horizontal Motor
(Standard Cab)................... 8W-80-40
Driver Power Seat Rear Vertical Motor
(Club Cab)....................... 8W-80-40
Driver Power Seat Rear Vertical Motor
(Standard Cab)................... 8W-80-40
Driver Power Seat Switch (Club Cab).... 8W-80-40
Driver Power Seat Switch
(Standard Cab)................... 8W-80-41
Driver Power Window Motor........... 8W-80-41
Electric Brake Provision.............. 8W-80-41
Engine Control Module (Diesel)........ 8W-80-41
Engine Coolant Temperature Sensor
(Diesel)......................... 8W-80-42
Engine Coolant Temperature Sensor
(Gas)........................... 8W-80-43
Engine Oil Pressure Sensor (Diesel)..... 8W-80-43
Engine Oil Pressure Sensor (Gas)....... 8W-80-43
EVAP/Purge Solenoid................ 8W-80-43
Front Washer Pump................. 8W-80-43
Fuel Heater (Diesel)................. 8W-80-43
Fuel Injection Pump (Diesel)........... 8W-80-44
Fuel Injector No. 1.................. 8W-80-44
Fuel Injector No. 2.................. 8W-80-44
Fuel Injector No. 3.................. 8W-80-44
Fuel Injector No. 4.................. 8W-80-44
Fuel Injector No. 5.................. 8W-80-45
Fuel Injector No. 6.................. 8W-80-45
Fuel Injector No. 7 (5.2L/5.9L/8.0L)..... 8W-80-45Component Page
Fuel Injector No. 8 (5.2L/5.9L/8.0L)..... 8W-80-45
Fuel Injector No. 9 (8.0L)............. 8W-80-45
Fuel Injector No. 10 (8.0L)............ 8W-80-46
Fuel Pump Module (Gas)............. 8W-80-46
Fuel Tank Module (Diesel)............ 8W-80-46
Fuel Transfer Pump (Diesel)........... 8W-80-46
G300............................. 8W-80-46
Generator......................... 8W-80-47
Glove Box Lamp And Switch........... 8W-80-47
Headlamp Switch C1................ 8W-80-47
Headlamp Switch C2................ 8W-80-47
Heated Mirror Switch................ 8W-80-48
High Note Horn.................... 8W-80-48
Idle Air Control Motor................ 8W-80-48
Ignition Coil (3.9L/5.2L/5.9L).......... 8W-80-48
Ignition Coil 4 Pack (8.0L)............ 8W-80-48
Ignition Coil 6 Pack (8.0L)............ 8W-80-49
Ignition Switch C1.................. 8W-80-49
Ignition Switch C2.................. 8W-80-49
Instrument Cluster C1............... 8W-80-49
Instrument Cluster C2............... 8W-80-50
Intake Air Heater Relays (Diesel)....... 8W-80-50
Intake Air Temperature Sensor (Diesel) . . 8W-80-50
Intake Air Temperature Sensor (Gas).... 8W-80-50
Joint Connector No. 1 (In PDC)........ 8W-80-50
Joint Connector No. 2 (In PDC)........ 8W-80-51
Joint Connector No. 5................ 8W-80-52
Joint Connector No. 6................ 8W-80-52
Joint Connector No. 7................ 8W-80-53
Joint Connector No. 8................ 8W-80-53
Junction Block C1................... 8W-80-54
Junction Block C2................... 8W-80-54
Junction Block C3................... 8W-80-54
Junction Block C4................... 8W-80-55
Junction Block C5................... 8W-80-55
Junction Block C6................... 8W-80-55
Junction Block C7................... 8W-80-55
Junction Block C8................... 8W-80-56
Junction Block C9................... 8W-80-56
Leak Detection Pump (Gas)........... 8W-80-56
Left Back-Up Lamp.................. 8W-80-57
Left Fog Lamp..................... 8W-80-57
Left Front Door Speaker (Premium)..... 8W-80-57
Left Front Door Speaker (Standard)..... 8W-80-57
Left Front Fender Lamp
(Dual Rear Wheels)................ 8W-80-57
Left Front Wheel Speed Sensor (ABS) . . . 8W-80-58
Left Headlamp..................... 8W-80-58
Left License Lamp.................. 8W-80-58
Left Outboard Clearance Lamp......... 8W-80-58
Left Outboard Headlamp............. 8W-80-58
Left Outboard Identification Lamp...... 8W-80-59
Left Park/Turn Signal Lamp........... 8W-80-59
Left Power Mirror................... 8W-80-59
8W - 80 - 2 8W-80 CONNECTOR PIN-OUTSBR/BE

ENGINE CONTROL MODULE (DIESEL) - 50 WAY
CAV CIRCUIT FUNCTION
12 K246 20YL/DG CUMMINS BUS (-)
13 K242 20WT DATA LINK (+) FUEL INJECTION PUMP
14 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
15 K135 18YL/WT TRANSFER PUMP SUPPLY
16 H105 18LG/DB IDLE VALIDATION SWITCH NO. 2
17 K124 18GY CAMSHAFT POSITION SENSOR SIGNAL
18 K48 18DG FUEL INJECTION PUMP SYNC SIGNAL
19 - -
20 - -
21 K1 18DG/RD WATER IN FUEL SENSOR SIGNAL
22 V37 18RD/LG SPEED CONTROL SWITCH SIGNAL
23 K240 20BK DATA LINK (-) FUEL INJECTOR PUMP
24 V32 18YL/RD BRAKE SWITCH SENSE
25 H102 18LB/BK ACCELERATOR PEDAL POSITION SENSOR SIGNAL
26 G113 18OR PTO SWITCH SENSE
27 - -
28 K22 18OR/DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL
29 S21 18YL/BK AIR INTAKE HEATER RELAY NO. 1
30 Z12 18BK/TN GROUND
31 H101 18DB/WT ACCELERATOR PEDAL POSITION SENSOR SUPPLY
32 H103 18BK/YL ACCELERATOR PEDAL POSITION SENSOR GROUND
33 K45 18LB/RD FUEL SHUT-OFF SIGNAL
34 K44 18VT/OR LOW IDLE SELECT
35 K135 18YL/WT TRANSFER PUMP SUPPLY
36 K131 18BR/WT FUEL INJECTOR PUMP RELAY CONTROL
37 G85 18OR/BK WAIT-TO-START WARNING INDICATOR DRIVER
38 D21 18PK/DB SCI TRANSMIT
39 D20 18DG SCI RECEIVE
40 D2 18WT/BK CCD BUS (-)
41 D1 18VT/BR CCD BUS (+)
42 - -
43 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
44 K243 20OR/BR DATA LINK SHIELD FUEL INJECTOR PUMP
45 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
46 - -
47 S22 18OR/BK AIR INTAKE HEATER RELAY CONTROL NO. 2
48 A14 18RD/WT FUSED B(+)
49 Z12 18BK/TN GROUND
50 A14 18RD/WT FUSED B(+)
ENGINE COOLANT TEMPERATURE SENSOR (DIESEL)-2WAY
CAV CIRCUIT FUNCTION
A K104 18BK/LB SENSOR GROUND
B K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
8W - 80 - 42 8W-80 CONNECTOR PIN-OUTSBR/BE

ENGINE COOLANT TEMPERATURE SENSOR (GAS)-2WAY
CAV CIRCUIT FUNCTION
1 K4 18BK/LB SENSOR GROUND
2 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
ENGINE OIL PRESSURE SENSOR (DIESEL) - GRAY 3 WAY
CAV CIRCUIT FUNCTION
A K7 18OR 5V SUPPLY
B K104 18BK/LB ENGINE OIL PRESSURE SENSOR RETURN
C G60 18GY/BK ENGINE OIL PRESSURE SENSOR SIGNAL
ENGINE OIL PRESSURE SENSOR (GAS)-2WAY
CAV CIRCUIT FUNCTION
1 K4 20BK/LB SENSOR GROUND
2 G60 18GY/OR ENGINE OIL PRESSURE SENSOR SIGNAL
EVAP/PURGE SOLENOID-2WAY
CAV CIRCUIT FUNCTION
1 K52 18PK/WT EVAPORATIVE EMISSION SOLENOID CONTROL
2 F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
WINDSHIELD WASHER PUMP - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 V10 16BR WASHER SWITCH SENSE
2 Z1 20BK GROUND
FUEL HEATER (DIESEL)-2WAY
CAV CIRCUIT FUNCTION
A Z11 14BK/TN GROUND
B A93 12RD/BK FUEL HEATER RELAY OUTPUT
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43

POWERTRAIN CONTROL MODULE C1 (DIESEL) - BLACK 32 WAY
CAV CIRCUIT FUNCTION
29 - -
30 - -
31 Z12 14BK/TN GROUND
32 Z12 14BK/TN GROUND
POWERTRAIN CONTROL MODULE C1 (GAS)- BLACK 32 WAY
CAV CIRCUIT FUNCTION
1 K32 18YL/GY(8.0L) IGNITION COIL NO. 4 DRIVER
2 F18 18LG/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 K18 18RD/BK(8.0L) IGNITION COIL NO. 3 DRIVER
4 K4 18BK/LB SENSOR GROUND
5 K43 18DG/GY(8.0L) IGNITION COIL NO. 5 DRIVER
6 T41 18BK/WT (A/T) PARK/NEUTRAL POSITION SWITCH SENSE
7 K19 18BK/GY IGNITION COIL NO.1
7 K19 18BK/GY(5.9L) IGNITION COIL NO. 1 DRIVER
8 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
9 K17 18DB/WT(8.0L) IGNITION COIL NO. 2 DRIVER
10 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
11 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
12 - -
13 G113 18OR PTO SWITCH SENSE
14 - -
15 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
16 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
17 K6 18VT/WT 5V SUPPLY
18 K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL
19 K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER
20 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
21 - -
22 A14 16RD/WT FUSED B(+)
23 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
24 K41 18BK/DG(5.9L/8.0L) OXYGEN SENSOR 1/1 SIGNAL
24 K141 18TN/WT(CALIFORNIA) OXYGEN SENSOR 1/1 SIGNAL
25 K341 18OR/BK(5.9L)(CALIFORNIA) OXYGEN SENSOR 1/2 SIGNAL
25 K341 18OR/BK(A/T)(CALIFORNIA) OXYGEN SENSOR 1/3 SIGNAL
26 K241 18LG/RD(CALIFORNIA) OXYGEN SENSOR 2/1 SIGNAL
26 K241 18LG/RD(8.0L/5.9L) OXYGEN SENSOR 2/1 SIGNAL
27 K1 18DG/RD MAP SENSOR SIGNAL
28 - -
29 K141 18TN/WT(8.0L)(A/T)(CALIFORNIA) OXYGEN SENSOR 1/2 SIGNAL
29 K441 18OR/TN(5.9L)(CALIFORNIA) OXYGEN SENSOR 2/2 SIGNAL
30 - -
31 Z12 14BK/TN GROUND
32 Z12 14BK/TN GROUND
A24 K141 18TN/WT(5.9L) OXYGEN SENSOR 1/1 SIGNAL
B24 K141 18TN/WT(5.9L) OXYGEN SENSOR 1/1 SIGNAL
8W - 80 - 70 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)

CONDITION POSSIBLE CAUSES CORRECTION
OIL PUMPING AT RINGS; SPARK
PLUGS FOULING1. Worn or damaged rings. 1. Hone cylinder bores and replace
rings.
2. Carbon in oil ring slots. 2. Replace rings.
3. Incorrect ring size installed. 3. Replace rings.
4. Worn valve guides. 4. Ream guides and replace valves.
5. Leaking intake gasket. 5. Replace intake gaskets.
6. Leaking valve guide seals. 6. Replace valve guide seals.
DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION PRESSURE
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise, the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs (Refer to 8 - ELEC-
TRICAL/IGNITION CONTROL/SPARK PLUG -
REMOVAL).
(3) Secure the throttle in the wide-open position.
(4) Disconnect the ignition coil.
(5) Insert a compression pressure gauge and rotate
the engine with the engine starter motor for three
revolutions.
(6) Record the compression pressure on the third
revolution. Continue the test for the remaining cylin-
ders.
(Refer to 9 - ENGINE - SPECIFICATIONS) for the
correct engine compression pressures.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing)
²Leaks between adjacent cylinders or into water
jacket²Any causes for combustion/compression pressure
loss
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM HOT COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn OFF the
engine.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.
Perform the test procedure on each cylinder accord-
ing to the tester manufacturer's instructions. While
testing, listen for pressurized air escaping through
the throttle body, tailpipe or oil filler cap opening.
Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder CYLINDER COMBUSTION
PRESSURE LEAKAGE DIAGNOSIS CHART .
BR/BEENGINE 5.9L 9 - 9
ENGINE 5.9L (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)

CONDITION POSSIBLE CAUSES CORRECTION
OIL PUMPING AT RINGS; SPARK
PLUGS FOULING1. Worn or damaged rings. 1. Hone cylinder bores and replace
rings.
2. Carbon in oil ring slots. 2. Replace rings.
3. Incorrect ring size installed. 3. Replace rings.
4. Worn valve guides. 4. Ream guides and replace valves.
5. Leaking intake gasket. 5. Replace intake gaskets.
6. Leaking valve guide seals. 6. Replace valve guide seals.
DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION PRESSURE
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise, the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs (Refer to 8 - ELEC-
TRICAL/IGNITION CONTROL/SPARK PLUG -
REMOVAL).
(3) Secure the throttle in the wide-open position.
(4) Disconnect the ignition coil.
(5) Insert a compression pressure gauge and rotate
the engine with the engine starter motor for three
revolutions.
(6) Record the compression pressure on the third
revolution. Continue the test for the remaining cylin-
ders.
(Refer to 9 - ENGINE - SPECIFICATIONS) for the
correct engine compression pressures.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing)
²Leaks between adjacent cylinders or into water
jacket²Any causes for combustion/compression pressure
loss
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM HOT COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn OFF the
engine.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.
Perform the test procedure on each cylinder accord-
ing to the tester manufacturer's instructions. While
testing, listen for pressurized air escaping through
the throttle body, tailpipe or oil filler cap opening.
Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder CYLINDER COMBUSTION
PRESSURE LEAKAGE DIAGNOSIS CHART.
9 - 64 ENGINE 8.0LBR/BE
ENGINE 8.0L (Continued)