engine DODGE RAM 2002 Service Repair Manual

INSTALLATION - 8.0L
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 powertrain control module (PCM).
(1) Clean the mating surfaces of the throttle body
and the intake manifold.
(2) Install new throttle body-to-intake manifold
gasket.
(3) Install throttle body to intake manifold.
(4) Install four mounting nuts. Tighten nuts to 22
N´m (192 in. lbs.) torque.
(5) Install control cables.
(6) Install electrical connectors.
(7) Install air cleaner housing to throttle body.
(8) Install 4 air cleaner housing mounting nuts.
Tighten nuts to 11 N´m (96 in. lbs.) torque.
(9) Install air cleaner housing cover.
THROTTLE CONTROL CABLE
REMOVAL
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing accelerator pedal or cables.
(1) From inside the vehicle, hold up the accelerator
pedal. Remove the plastic cable retainer and throttle
cable core wire from upper end of pedal arm (Fig.
21). The plastic cable retainer snaps into pedal the
arm.
(2) Remove the cable core wire at the pedal arm.
(3) Remove the air cleaner housing.
(4) From inside the vehicle, pinch both sides of the
plastic cable housing retainer tabs at the dash panel
(Fig. 21).
(5) Remove cable housing from dash panel and
pull the cable into the engine compartment.
(6)5.9L Engines:Disconnect the cable from the
routing/holddown clip at the radiator fan shroud.
(7)8.0L V-10 Engine:Remove the throttle cable
socket at throttle lever ball. (Fig. 44) (snaps off).
(8)5.9L Engines:Slip the cable end rearward
from pin on throttle body (Fig. 43).
(9) Remove cable housing at throttle body mount-
ing bracket by pressing on release tab with a small
screwdriver (Fig. 45) or (Fig. 44).To prevent cable
housing breakage, press on the tab only enough
to release the cable from the bracket.Lift the
cable housing straight up from bracket while press-
ing on release tab. Remove throttle cable from vehi-
cle.
Fig. 43 Throttle Cable at Throttle BodyÐ5.9L
EnginesÐTypical
1 - THROTTLE LEVER PIN
2 - CAM (V-8 ENGINE ONLY)
3 - THROTTLE CABLE END
Fig. 44 Throttle Cable at Throttle BodyÐ8.0L V-10
Engine
1 - PRESS TAB FOR CABLE REMOVAL
2 - THROTTLE CABLE
3 - CABLE SOCKET
4 - LEVER BALL
5 - MOUNTING BRACKET
BR/BEFUEL INJECTION - GASOLINE 14 - 49
THROTTLE BODY (Continued)

INSTALLATION
(1)5.9L Engines:
(a) Rotate and hold the throttle cam in the full
wide open position. Snap the cable end onto lever
pin (Fig. 43).
(b) Connect cable to throttle body mounting
bracket (push down and lock).
(c) Connect cable to fan shroud routing clip.
(2)8.0L V-10 Engine:
(a) Connect cable end socket to throttle body
lever ball (snaps on) (Fig. 44).
(b) Connect cable to throttle body mounting
bracket (push down and lock).
(3) Install the remaining cable housing end into
and through the dash panel opening (snaps into posi-
tion). The two plastic pinch tabs (Fig. 21) should lock
the cable to dash panel.
(4) From inside the vehicle, hold up the accelera-
tor pedal. Install the throttle cable core wire and
plastic cable retainer into and through the upper end
of the pedal arm (the plastic retainer is snapped into
the pedal arm). When installing the plastic retainer
to the accelerator pedal arm, note the index tab on
the pedal arm (Fig. 21). Align the index slot on the
plastic cable retainer to this index tab.
THROTTLE POSITION SENSOR
DESCRIPTION
The 3±wire Throttle Position Sensor (TPS) is
mounted on the throttle body and is connected to the
throttle blade.
OPERATION
The TPS is a 3±wire variable resistor that provides
the Powertrain Control Module (PCM) with an input
signal (voltage) that represents the throttle blade
position of the throttle body. The sensor is connected
to the throttle blade shaft. As the position of the
throttle blade changes, the resistance (output volt-
age) of the TPS changes.
The PCM supplies approximately 5 volts to the
TPS. The TPS output voltage (input signal to the
PCM) represents the throttle blade position. The
PCM receives an input signal voltage from the TPS.
This will vary in an approximate range of from .26
volts at minimum throttle opening (idle), to 4.49 volts
at wide open throttle. Along with inputs from other
sensors, the PCM uses the TPS input to determine
current engine operating conditions. In response to
engine operating conditions, the PCM will adjust fuel
injector pulse width and ignition timing.
The PCM needs to identify the actions and position
of the throttle blade at all times. This information is
needed to assist in performing the following calcula-
tions:
²Ignition timing advance
²Fuel injection pulse-width
²Idle (learned value or minimum TPS)
²Off-idle (0.06 volt)
²Wide Open Throttle (WOT) open loop (2.608
volts above learned idle voltage)
²Deceleration fuel lean out
²Fuel cutoff during cranking at WOT (2.608 volts
above learned idle voltage)
²A/C WOT cutoff (certain automatic transmis-
sions only)
REMOVAL
REMOVAL - 5.9L
The TPS is located on the side of the throttle body.
(1) Remove air intake tube at throttle body.
(2) Disconnect TPS electrical connector.
(3) Remove two TPS mounting bolts (Fig. 46).
(4) Remove TPS from throttle body.
REMOVAL - 8.0L
The TPS is located on the side of the throttle body
(Fig. 47).
(1) Remove air intake tube at air cleaner housing.
(2) Remove the air cleaner cover.
(3) Remove the 4 air cleaner housing mounting
nuts and remove housing from throttle body.
(4) Disconnect TPS electrical connector.
(5) Remove two TPS mounting bolts (Fig. 47).
(6) Remove TPS from throttle body.
Fig. 45 Cable Release
1-TAB
14 - 50 FUEL INJECTION - GASOLINEBR/BE
THROTTLE CONTROL CABLE (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)

(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 cleaner housing to throttle body.
(6) Install 4 air cleaner housing mounting nuts.
Tighten nuts to 11 N´m (96 in. lbs.) torque.
(7) Install air cleaner housing cover.
(8) Install air intake tube to cover.
FUEL INJECTOR
DESCRIPTION
A separate fuel injector (Fig. 50) is used for each
individual cylinder.
OPERATION
OPERATION
The fuel injectors are electrical solenoids. The
injector contains a pintle that closes off an orifice at
the nozzle end. When electric current is supplied to
the injector, the armature and needle move a short
distance against a spring, allowing fuel to flow out
the orifice. Because the fuel is under high pressure, a
fine spray is developed in the shape of a pencil
stream. The spraying action atomizes the fuel, add-
ing it to the air entering the combustion chamber.
An individual fuel injector is used for each individ-
ual cylinder. The top (fuel entry) end of the injector is
attached into an opening on the fuel rail.The nozzle (outlet) ends of the injectors are posi-
tioned into openings in the intake manifold just
above the intake valve ports of the cylinder head.
The engine wiring harness connector for each fuel
injector is equipped with an attached numerical tag
(INJ 1, INJ 2 etc.). This is used to identify each fuel
injector.
The injectors are energized individually in a
sequential order by the Powertrain Control Module
(PCM). The PCM will adjust injector pulse width by
switching the ground path to each individual injector
on and off. Injector pulse width is the period of time
that the injector is energized. The PCM will adjust
injector pulse width based on various inputs it
receives.
Battery voltage is supplied to the injectors through
the ASD relay.
The PCM determines injector pulse width based on
various inputs.
OPERATION - PCM OUTPUT
The nozzle ends of the injectors are positioned into
openings in the intake manifold just above the intake
valve ports of the cylinder head. The engine wiring
harness connector for each fuel injector is equipped
with an attached numerical tag (INJ 1, INJ 2 etc.).
This is used to identify each fuel injector with its
respective cylinder number.
The injectors are energized individually in a
sequential order by the Powertrain Control Module
(PCM). The PCM will adjust injector pulse width by
switching the ground path to each individual injector
on and off. Injector pulse width is the period of time
that the injector is energized. The PCM will adjust
injector pulse width based on various inputs it
receives.
Battery voltage (12 volts +) is supplied to the injec-
tors through the ASD relay. The ASD relay will shut-
down the 12 volt power source to the fuel injectors if
the PCM senses the ignition is on, but the engine is
not running. This occurs after the engine has not
been running for approximately 1.8 seconds.
The PCM determines injector on-time (pulse width)
based on various inputs.
Fig. 50 Fuel Injector
1 - FUEL INJECTOR
2 - NOZZLE
3 - TOP (FUEL ENTRY)
14 - 52 FUEL INJECTION - GASOLINEBR/BE
THROTTLE POSITION SENSOR (Continued)

DIAGNOSIS AND TESTING - FUEL INJECTOR
To perform a complete test of the fuel injectors and
their circuitry, use the DRB scan tool and refer to the
appropriate Powertrain Diagnostics Procedures man-
ual. To test the injector only, refer to the following:
Disconnect the fuel injector wire harness connector
from the injector. The injector is equipped with 2
electrical terminals (pins). Place an ohmmeter across
the terminals. Resistance reading should be approxi-
mately 12 ohms  1.2 ohms at 20ÉC (68ÉF).
REMOVAL
(1) Remove air cleaner assembly.
(2) Remove fuel injector rail assembly. Refer to
Fuel Injector Rail removal in this section.
(3) Remove the clip(s) retaining the injector(s) to
fuel rail (Fig. 51) or (Fig. 52).
(4) Remove injector(s) from fuel rail.
INSTALLATION
(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.
(3) Install fuel rail assembly. Refer to Fuel Injector
Rail installation.
(4) Install air cleaner.
(5) Start engine and check for leaks.
Fig. 51 Fuel Injector MountingÐTypical
1 - CLIP
2 - INJECTOR
3 - FUEL RAIL
Fig. 52 Injector Retaining ClipsÐTypical Injector
1 - PLIERS
2 - INJECTOR CLIP
3 - FUEL INJECTOR
4 - FUEL RAIL
BR/BEFUEL INJECTION - GASOLINE 14 - 53
FUEL INJECTOR (Continued)

FUEL DELIVERY - DIESEL
TABLE OF CONTENTS
page page
FUEL DELIVERY - DIESEL
DESCRIPTION
DESCRIPTION - DIESEL FUEL DELIVERY
SYSTEM............................55
OPERATION.........................55
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FUEL SYSTEM
AIR LEAK VACUUM TEST...............57
DIAGNOSIS AND TESTING - AIR IN FUEL
SYSTEM............................60
DIAGNOSIS AND TESTING - FUEL SUPPLY
RESTRICTIONS.......................60
STANDARD PROCEDURE
STANDARD PROCEDURES - WATER
DRAINING AT FUEL FILTER..............61
STANDARD PROCEDURES - CLEANING
FUEL SYSTEM PARTS.................61
STANDARD PROCEDURE - AIR BLEED....61
SPECIFICATIONS
FUEL SYSTEM PRESSURESÐDIESEL
ENGINES............................62
FUEL INJECTOR FIRING ORDERÐDIESEL . 62
SPECIAL TOOLS
DIESEL FUEL SYSTEM.................63
FUEL FILTER / WATER SEPARATOR
DESCRIPTION.........................63
OPERATION...........................63
REMOVAL.............................64
INSTALLATION.........................65
FUEL HEATER
DESCRIPTION.........................66
OPERATION...........................66
DIAGNOSIS AND TESTING - FUEL HEATER . . . 66
REMOVAL/INSTALLATION................67
FUEL HEATER RELAY
DESCRIPTION.........................67
OPERATION...........................67
DIAGNOSIS AND TESTING - FUEL HEATER
RELAY..............................68
REMOVAL.............................69
INSTALLATION.........................69
FUEL INJECTION PUMP
DESCRIPTION
DESCRIPTIONÐFUEL PUMP 245 H.P......69
DESCRIPTIONÐFUEL PUMP 235 H.P......69
OPERATION...........................70
DIAGNOSIS AND TESTINGÐFUEL INJECTION
PUMP TIMING........................70REMOVAL.............................72
INSTALLATION.........................75
FUEL INJECTION PUMP DATA PLATE
SPECIFICATIONS
FUEL INJECTION PUMP DATA PLATE......77
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION.........................77
OPERATION...........................77
FUEL LINES
DESCRIPTION
DESCRIPTION........................77
DESCRIPTIONÐHIGH PRESSURE FUEL
LINES..............................78
OPERATIONÐHIGH PRESSURE FUEL LINES . 78
DIAGNOSIS AND TESTING - HIGH-
PRESSURE FUEL LINE LEAKS...........78
REMOVAL.............................79
INSTALLATION.........................81
FUEL TANK
DESCRIPTION - DIESEL FUEL TANK........82
FUEL TANK MODULE
DESCRIPTION.........................82
OPERATION...........................82
REMOVAL.............................83
INSTALLATION.........................83
FUEL TRANSFER PUMP
DESCRIPTION.........................83
OPERATION...........................83
DIAGNOSIS AND TESTING - FUEL TRANSFER
PUMP PRESSURE.....................84
REMOVAL.............................86
INSTALLATION.........................87
OVERFLOW VALVE
DESCRIPTION.........................87
OPERATION...........................87
DIAGNOSIS AND TESTING - OVERFLOW
VALVE ..............................87
REMOVAL.............................88
INSTALLATION.........................88
WATER IN FUEL SENSOR
DESCRIPTION.........................89
OPERATION...........................89
REMOVAL.............................89
FUEL DRAIN MANIFOLD
DESCRIPTION.........................89
OPERATION...........................89
REMOVAL.............................90
INSTALLATION.........................90
14 - 54 FUEL DELIVERY - DIESELBR/BE

FUEL DELIVERY - DIESEL
DESCRIPTION
DESCRIPTION - DIESEL FUEL DELIVERY
SYSTEM
The fuel system on the Cummins 24 valveÐTurbo
Diesel Engine uses anelectronically controlled
fuel injection pump with three control modules.
Also refer to the Powertrain Control Module (PCM)
or Engine Control Module sections.
Some fuel system components are shown in (Fig.
1).
The fuel delivery system consists of the:
²Accelerator pedal
²Air cleaner housing/element
²Fuel drain manifold (passage)
²Fuel filter/water separator
²Fuel heater
²Fuel heater relay
²Fuel transfer (lift) pump
²Fuel injection pump
²Fuel injectors
²Fuel heater temperature sensor
²Fuel tank
²Fuel tank filler/vent tube assembly²Fuel tank filler tube cap
²Fuel tank module containing the rollover valve,
fuel gauge sending unit (fuel level sensor) and a sep-
arate fuel filter located at bottom of tank module
²Fuel tubes/lines/hoses
²High-pressure fuel injector lines
²In-tank fuel filter (at bottom of fuel tank mod-
ule)
²Low-pressure fuel supply lines
²Low-pressure fuel return line
²Overflow valve
²Quick-connect fittings
²Throttle cable
²Water draining
OPERATION
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 120,000 KPA (17,405
PSI). USE EXTREME CAUTION WHEN INSPECTING
FOR HIGH-PRESSURE FUEL LEAKS. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. HIGH FUEL INJECTION PRESSURE
CAN CAUSE PERSONAL INJURY IF CONTACT IS
MADE WITH THE SKIN.
BR/BEFUEL DELIVERY - DIESEL 14 - 55

Fig. 1 FUEL SYSTEM COMPONENTS - DIESEL
1 - ENGINE COOLANT TEMPERATURE (ECT) SENSOR 14 - FUEL SUPPLY LINE (LOW-PRESSURE, TO ENGINE)
2 - THROTTLE LEVER BELLCRANK AND APPS (ACCELERATOR
PEDAL POSITION SENSOR)15 - FUEL TRANSFER (LIFT) PUMP
3 - INTAKE MANIFOLD AIR HEATER/ELEMENTS 16 - OIL PRESSURE SENSOR
4 - HIGH-PRESSURE FUEL LINES 17 - FUEL FILTER/WATER SEPARATOR
5 - FUEL HEATER 18 - DRAIN TUBE
6 - FUEL PRESSURE TEST PORT 19 - WATER-IN-FUEL (WIF) SENSOR
7 - MAP (BOOST) SENSOR 20 - ENGINE CONTROL MODULE (ECM)
8 - FUEL INJECTORS 21 - FUEL PRESSURE TEST PORT
9 - FUEL INJECTOR CONNECTOR 22 - CAMSHAFT POSITION SENSOR (CMP)
10 - INTAKE AIR TEMPERATURE (IAT) SENSOR 23 - OVERFLOW VALVE
11 - FUEL DRAIN MANIFOLD 24 - FUEL INJECTION PUMP
12 - DRAIN VALVE 25 - FUEL HEATER TEMPERATURE SENSOR (THERMOSTAT)
13 - FUEL RETURN LINE (TO FUEL TANK)
14 - 56 FUEL DELIVERY - DIESELBR/BE
FUEL DELIVERY - DIESEL (Continued)

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FUEL SYSTEM AIR
LEAK VACUUM TEST
The proceeding test will determine if a fuel system
air leak exists at the engine. Air leaks will cause
hard starting and/or poor performance.
A hand-operated vacuum pump/gauge equipped
with a remote or built-on fluid container will be used.
A typical hand-operated pump is shown in (Fig. 2).
The use of a hand-operated pumpwitha fluid con-
tainer will prevent fuel oil from entering and possibly
damaging pump. Two rubber caps (one 5/16º and one
3/8º) will also be used to temporarily plug / seal fuel
system.
Vacuum Test Set-Up, Specifications and
Conditions
²Examine all engine fuel system components, fit-
tings, lines and hoses for visual evidence of fuel leak-
age. Repair as necessary before proceeding.
²Be sure gauge on your hand-operated pump is
accurate and pump does not leak. Perform a simple
test on pump. Add a 3 foot section (minimum) of
clear plastic hose to the pump.
²Apply maximum 15-20 inches of vacuum for
tests.
²System should hold 15-20 inches of vacuum for 5
continuous minutes. After 5 minutes, vacuum should
not drop more than 0.1 inch Hg for 1 minute.²Disconnect fuel supply and return lines (quick-
connects) at rear of engine (Fig. 3).
²Drain as much fuel as possible from engine fuel
lines. Also, completely drain fuel filter/water separa-
tor housing. Refer to Fuel Filter/Water Separator
Removal and Installation for fuel draining proce-
dures. This step must be done to prevent liquid fuel
from entering and possibly damaging your hand-op-
erated pump.
Testing All Engine Fuel System Components Together
This test will indicate an air leak is present some-
where on the engine.
(1) Be sure water drain valve is securely closed.
(2) Examine all engine fuel system components,
fittings, lines and hoses for visual evidence of fuel
leakage. Repair as necessary.
(3) Install 5/16º rubber cap to fuel return line on
engine (Fig. 4).
(4) Install hand-operated vacuum pump to fuel
supply line on engine (Fig. 4).
(5) Perform vacuum test. Be careful not to allow
liquid fuel to get into your hand-operated vacuum
pump.
(6) Vacuum holds ? End of test; no leaks found on
engine.
(7) Vacuum leak ? Proceed. The following tests will
isolate the component that is leaking.
Fig. 2 HAND-OPERATED VACUUM PUMP (TYPICAL)
1 - PUMP
2 - CONTAINER
Fig. 3 QUICK-CONNECT FITTINGS LOCATION
1 - FUEL SUPPLY LINE
2 - SUPPORT BRACKET BOLT
3 - FUEL RETURN LINE
4 - QUICK-CONNECT FITTINGS (2)
BR/BEFUEL DELIVERY - DIESEL 14 - 57

(b) Remove all high-pressure fuel lines at injec-
tor high-pressure connectors. Examine all injector
connector o-rings. If any damage to o-ring exists,
replace connector.
(c) If no damage is found at connectors, remove
all 6 fuel injectors to inspect o-rings and sealing
washers. Also inspect cylinder head bores where
these sealing washers make contact. The bore con-
tact area should be smooth and uniform.
(7) Vacuum holds ? Proceed.
Testing VP-44 Pump and its Return Line
(1) Remove rubber 3/8º sealing cap and reconnect /
tighten fuel drain line to top of ªTº fitting (Fig. 8).
(2) Disconnect and separate VP-44 drain line at
front of ªTº fitting (Fig. 9). To plug / seal system,
install 3/8º rubber cap to this disconnected line (Fig.
9).
(3) Disconnect rubber fuel hose at VP-44 inlet (Fig.
10). Connect your hand-operated vacuum pump at
this inlet point.
(4) Perform vacuum test. Be careful not to allow
liquid fuel to get into your hand-operated vacuum
pump.
Fig. 6 FUEL HOSE AT FUEL FILTER
1 - TEST PORT FITTING
2 - VP-44 FUEL INLET LINE
3 - RUBBER FUEL HOSE
4 - FUEL FILTER OUTLET LINE
5 - HOSE CLAMPS (2)
6 - VP-44 INJECTION PUMP
Fig. 7 CAPPING OFF FUEL FILTER OUTLET LINE
1 - FUEL FILTER / WATER SEPARATOR
2 - OUTLET LINE
3 - RUBBER CAP
Fig. 8(T(FITTING - TOP DISCONNECTED
1 - RUBBER SEAL/GASKET
2 - FUEL DRAIN LINE AT TOP OF9T9FITTING (FROM REAR OF
CYLINDER HEAD)
3 - RUBBER CAP
4-9T9FITTING
5 - LEFT REAR CORNER OF ENGINE
6 - SUPPORT BRACKET BOLT
BR/BEFUEL DELIVERY - DIESEL 14 - 59
FUEL DELIVERY - DIESEL (Continued)