engine DODGE RAM 2002 Service Repair Manual

(8)Latch Clips:Depending on vehicle model and
engine, 2 different types of safety latch clips are used
(Fig. 50) or (Fig. 51). Type-1 is tethered to fuel line
and type-2 is not. A special tool will be necessary to
disconnect fuel line after latch clip is removed. The
latch clip may be used on certain fuel line/fuel rail
connection, or to join fuel lines together.
(a) Type 1: Pry up on latch clip with a screw-
driver (Fig. 50).
(b) Type 2: Separate and unlatch 2 small arms
on end of clip (Fig. 51) and swing away from fuel
line.
(c) Slide latch clip toward fuel rail while lifting
with screwdriver.
(d) Insert special fuel line removal tool (Snap-On
number FIH 9055-1 or equivalent) into fuel line
(Fig. 52). Use tool to release locking fingers in end
of line.
(e) With special tool still inserted, pull fuel line
from fuel rail.
(f) After disconnection, locking fingers will
remain within quick-connect fitting at end of fuel
line.
(9) Disconnect quick-connect fitting from fuel sys-
tem component being serviced.CONNECTING
(1) Inspect quick-connect fitting body and fuel sys-
tem component for damage. Replace as necessary.
(2) Prior to connecting quick-connect fitting to
component being serviced, check condition of fitting
and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.
(3) Insert quick-connect fitting into fuel tube or
fuel system component until built-on stop on fuel
tube or component rests against back of fitting.
(4) Continue pushing until a click is felt.
(5) Single-tab type fitting: Push new tab down
until it locks into place in quick-connect fitting.
(6) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.).
(7) Latch Clip Equipped: Install latch clip (snaps
into position).If latch clip will not fit, this indi-
cates fuel line is not properly installed to fuel
rail (or other fuel line). Recheck fuel line con-
nection.
(8) Connect negative cable to battery.
(9) Start engine and check for leaks.
BR/BEFUEL DELIVERY - GASOLINE 14 - 27
QUICK CONNECT FITTING (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

FUEL INJECTION - GASOLINE
DIAGNOSIS AND TESTING
VISUAL INSPECTIONÐ5.9L ENGINES
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. 1).
(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. 2). Refer to
label on PDC cover for relay location.
(4) Inspect ignition coil connections. Verify that
coil secondary cable is firmly connected to coil (Fig.
3).
(5) Verify that distributor cap is correctly attached
to distributor. Be sure that spark plug cables are
firmly connected to the distributor cap and the spark
plugs are in their correct firing order. Be sure that
coil cable is firmly connected to distributor cap and
coil. Be sure that camshaft position sensor wire con-nector (at the distributor) is firmly connected to har-
ness 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 positive crankcase ventilation (PCV)
valve operation. Refer to 25, Emission Control Sys-
tem for additional information. Verify PCV valve
hose is firmly connected to PCV valve and manifold
(Fig. 4).
Fig. 1 Powertrain Control Module (PCM)
1 - PCM MOUNTING BOLTS (3)
2 - POWERTRAIN CONTROL MODULE (PCM)
3 - (3) 32±WAY CONNECTORS
Fig. 2 Power Distribution Center (PDC)
1 - POWER DISTRIBUTION CENTER (PDC)
Fig. 3 Ignition CoilÐ5.9L EnginesÐTypical
1 - ACCESSORY DRIVE BELT TENSIONER
2 - COIL CONNECTOR
3 - IGNITION COIL
4 - COIL MOUNTING BOLTS
BR/BEFUEL INJECTION - GASOLINE 14 - 29

(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.
(11) Inspect accelerator cable, transmission throt-
tle cable (if equipped) and cruise control cable con-
nections (if equipped). Check their connections to the
throttle arm of throttle body for any binding or
restrictions.
(12) If equipped with vacuum brake booster, verify
that vacuum booster hose is firmly connected to fit-
ting on intake manifold. Also check connection to
brake vacuum booster.
(13) Inspect the air cleaner inlet and air cleaner
element for dirt or restrictions.
(14) Inspect radiator grille area, radiator fins and
air conditioning condenser for restrictions.
(15) Verify that the intake manifold air tempera-
ture sensor wire connector is firmly connected to har-
ness connector (Fig. 5).
(16) Verify that MAP sensor electrical connector is
firmly connected to MAP sensor (Fig. 6). Also verify
that rubber L-shaped fitting from MAP sensor to the
throttle body is firmly connected (Fig. 7).
(17) Verify that fuel injector wire harness connec-
tors are firmly connected to injectors in the correct
order. Each harness connector is numerically tagged
with the injector number (INJ 1, INJ 2 etc.) of its
corresponding fuel injector and cylinder number.
(18) Verify harness connectors are firmly con-
nected to idle air control (IAC) motor, throttle posi-
tion sensor (TPS) and manifold absolute pressure
(MAP) sensor (Fig. 6).(19) Verify that wire harness connector is firmly
connected to the engine coolant temperature sensor
(Fig. 8).
(20) Raise and support the vehicle.
(21) Verify oxygen sensor wire connectors are
firmly connected to the sensors. Inspect sensors and
connectors for damage (Fig. 9), (Fig. 10) or (Fig. 11).
Fig. 4 PCV Valve
1 - P C V VA LV E
2 - PCV VALVE HOSE CONNECTIONS
Fig. 5 Air Temperature
1 - INTAKE MANIFOLD AIR TEMPERATURE SENSOR
2 - ELECTRICAL CONNECTOR
Fig. 6 Sensor and IAC Motor LocationÐTypical (V-8
Shown)
1 - MAP SENSOR
2 - IDLE AIR CONTROL MOTOR
3 - THROTTLE POSITION SENSOR
14 - 30 FUEL INJECTION - GASOLINEBR/BE
FUEL INJECTION - GASOLINE (Continued)

(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)

(11) Inspect accelerator cable, transmission throt-
tle cable (if equipped) and cruise control cable con-
nections (if equipped). Check their connections to the
throttle arm of throttle body for any binding or
restrictions.
(12) If equipped with vacuum brake booster, verify
that vacuum booster hose is firmly connected to fit-
ting on intake manifold. Also check connection to
brake vacuum booster.
(13) Inspect the air cleaner inlet and air cleaner
element for dirt or restrictions.
(14) Inspect radiator grille area, radiator fins and
air conditioning condenser for restrictions.
(15) Verify that the intake manifold air tempera-
ture sensor wire connector is firmly connected to har-
ness connector (Fig. 15).(16) Verify that MAP sensor electrical connector is
firmly connected to MAP sensor (Fig. 16).
(17) Verify that fuel injector wire harness connec-
tors are firmly connected to injectors in the correct
order. Each harness connector is numerically tagged
with the injector number (INJ 1, INJ 2 etc.) of its
corresponding fuel injector and cylinder number.
(18) Verify harness connectors are firmly con-
nected to idle air control (IAC) motor and throttle
position sensor (TPS).
(19) Verify that wire harness connector is firmly
connected to the engine coolant temperature sensor
(Fig. 17).
Fig. 14 Ignition Coil PackÐ8.0L Engine
Fig. 15 Air Temperature SensorÐ8.0L Engine
1 - INTAKE MANIFOLD AIR TEMP. SENSOR
2 - INTAKE MANIFOLD
Fig. 16 Map Sensor Ð8.0L Engine
1 - MAP SENSOR
2 - MOUNTING BOLTS
3 - THROTTLE BODY
Fig. 17 Engine Coolant Temperature SensorÐ8.0L
Engine
1 - ENGINE COOLANT TEMP. SENSOR
2 - THERMOSTAT HOUSING
3 - GENERATOR
BR/BEFUEL INJECTION - GASOLINE 14 - 33
FUEL INJECTION - GASOLINE (Continued)

SPECIFICATIONS - TORQUE - GAS FUEL INJECTION
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Air Cleaner Housing
Mount. NutsÐ8.0L Engine11 9 6
Air Cleaner Housing Metal
ClampÐ5.9L Engines435
Crankshaft Position
Sensor Mounting
BoltsÐAll Engines870
Camshaft Position Sensor
MountingÐ8.0L Engine650
Engine Coolant
Temperature SensorÐAll
Engines6-8 55-75
Fuel Tank Mounting Nuts 41 30
Fuel Hose Clamps 1 10
IAC Motor-To-Throttle
Body Bolts760
Intake Manifold Air Temp.
SensorÐAll Engines12-15 110-130
MAP Sensor Mounting
ScrewsÐ5.9L Engines325
MAP Sensor Mounting
ScrewsÐ8.0L Engine220
Oxygen SensorÐAll
Engines30 22
Powertrain Control Module
Mounting Screws435
Throttle Body Mounting
BoltsÐ5.9L Engines23 200
Throttle Body Mounting
BoltsÐ8.0L Engine22 192
Throttle Position Sensor
Mounting ScrewsÐAll
Engines760
SPECIAL TOOLS
FUEL SYSTEM
Spanner WrenchÐ6856
Fitting, Air MeteringÐ6714
BR/BEFUEL INJECTION - GASOLINE 14 - 35
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)