key DODGE RAM 2002 Service Workshop Manual

JOINT CONNECTOR NO.5-NATURAL 22 WAY
CAV CIRCUIT FUNCTION
1 M1 20PK FUSED B(+)
2 M1 22PK FUSED B(+)
3 M1 22PK FUSED B(+)
4 Z3 20BK/OR GROUND
5 Z3 18BK/OR GROUND
6 Z3 22BK/OR GROUND
7 Z3 18BK/OR GROUND
8 E2 22OR PANEL LAMPS FEED
9 E2 22OR PANEL LAMPS FEED
10 E2 22OR PANEL LAMPS FEED
11 - -
12 M1 22PK FUSED B(+)
13 M1 22PK FUSED B(+)
14 Z3 20BK/OR (HEATED SEATS) GROUND
15 Z3 20BK/OR (HEATED SEATS) GROUND
16 Z3 22BK/OR (EXCEPT BASE/MIDLINE) GROUND
17 Z3 22BK/OR (EXCEPT BASE/MIDLINE) GROUND
18 - -
19 - -
20 E2 22OR PANEL LAMPS FEED
21 E2 22OR PANEL LAMPS FEED
22 E2 22OR PANEL LAMPS FEED
JOINT CONNECTOR NO.6-NATURAL 22 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3- -
4 L50 16WT/TN BRAKE LAMP SWITCH OUTPUT
5 L50 16WT/TN BRAKE LAMP SWITCH OUTPUT
6 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
7 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
8 Z9 16BK/VT(EXCEPT BASE/LOWLINE) GROUND
9 Z9 20BK/VT(SLT+HIGHLINE) GROUND
10 X3 20BK/RD(EXCEPT BASE/MIDLINE) HORN RELAY CONTROL
10 M22 22WT(BASE/MIDLINE) DOME LAMPS SWITCH SENSE
11 X3 20BK/RD(EXCEPT BASE/MIDLINE) HORN RELAY CONTROL
11 M22 22WT(BASE/MIDLINE) DOME LAMPS SWITCH SENSE
12 M22 22WT(BASE/MIDLINE) DOME LAMPS SWITCH SENSE
12 X3 20BK/RD(EXCEPT BASE/MIDLINE) HORN RELAY CONTROL
13 V10 16BR WASHER SWITCH SENSE
14 V10 16BR WASHER SWITCH SENSE
15 V10 16BR WASHER SWITCH SENSE
16 - -
17 - -
18 Z9 16BK/VT GROUND
19 Z9 16BK/VT(XECEPT BASE/LOWLINE) GROUND
20 G26 22LB KEY-IN IGNITION SWITCH SENSE
21 G26 22LB KEY-IN IGNITION SWITCH SENSE
22 G26 22LB KEY-IN IGNITION SWITCH SENSE
8W - 80 - 52 8W-80 CONNECTOR PIN-OUTSBR/BE

Inspect oil pressure relief valve plunger for scoring
and free operation in its bore. Small marks may be
removed with 400-grit wet or dry sandpaper.
The relief valve spring has a free length of approx-
imately 49.5 mm (1.95 inches). The spring should
test between 19.5 and 20.5 pounds when compressed
to 34 mm (1-11/32 inches). Replace spring that fails
to meet these specifications (Fig. 63).
If oil pressure was low and pump is within specifi-
cations, inspect for worn engine bearings or other
reasons for oil pressure loss.
ASSEMBLY
(1) Install pump rotors and shaft, using new parts
as required.
Fig. 59 Measuring Inner Rotor Thickness
Fig. 60 Measuring Outer Rotor Clearance in
Housing
1 - PUMP BODY
2 - OUTER ROTOR
3 - FEELER GAUGE
Fig. 61 Measuring Clearance Between Rotors
1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR
Fig. 62 Measuring Clearance Over Rotors
1 - STRAIGHT EDGE
2 - FEELER GAUGE
Fig. 63 Proper Installation of Retainer Cap
1 - RETAINER CAP
2 - CHAMFER
3 - COTTER KEY
BR/BEENGINE 5.9L 9 - 49
OIL PUMP (Continued)

move. It may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads
installed, apply 14 N´m (30 ft. lbs.) torque in the
reverse direction. With the cylinder heads removed,
apply 20 N´m (15 ft. lbs.) torque in the reverse direc-
tion. Note the amount of chain movement (Fig. 74).
(4) Install a new timing chain, if its movement
exceeds 3.175 mm (1/8 inch).
INSTALLATION
(1) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(2) Place timing chain around both sprockets.
(3) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(4) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(5) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 75).
(6) Install the camshaft bolt. Tighten the bolt to 68
N´m (50 ft. lbs.) torque.
(7) Check camshaft end play. The end play should
be 0.051-0.152 mm (0.002-0.006 inch) with a new
thrust plate and up to 0.254 mm (0.010 inch) with a
used thrust plate. If not within these limits install a
new thrust plate.
(8) Install the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
Fig. 73 Alignment of Timing Marks
1 - TIMING MARKS
Fig. 74 Measuring Timing Chain Stretch
1 - TORQUE WRENCH
2 - 3.175 MM
(0.125 IN.)
Fig. 75 Alignment of Timing Marks
1 - TIMING MARKS
BR/BEENGINE 5.9L 9 - 55
TIMING BELT/CHAIN AND SPROCKETS (Continued)

INSTALLATION
INSTALLATIONÐCAMSHAFT BEARINGS
(1) Install new camshaft bearings using recom-
mended Tool 8544 Camshaft Bushing Remover
Installer, by sliding the new camshaft bearing shell
over proper adapter.
(2) Bearings must be carefully aligned to bring oil
holes into full register with oil passages from the
main bearing. If the camshaft bearing shell oil holes
are not in exact alignment, remove and install them
correctly. Install a new core hole plug at the rear of
camshaft.Be sure this plug does not leak.
INSTALLATIONÐCAMSHAFT
(1) Lubricate camshaft lobes and camshaft bearing
journals. Using a long bolt, insert the camshaft into
the cylinder block.
NOTE: Whenever an engine has been rebuilt, a new
camshaft and/or new tappets installed, add 1 pint of
MoparTCrankcase Conditioner, or equivalent. The
oil mixture should be left in engine for a minimum
of 805 km (500 miles). Drain at the next normal oil
change.
(2) Install camshaft thrust plate. Tighten the torx
bolts to 22 N´m (16 ft. lbs.) torque.
(3) Check camshaft end play. The end play should
be 0.051-0.152 mm (0.002-0.006 inch) with a new
thrust plate and up to 0.254 mm (0.010 inch) with a
used thrust plate. If not within these limits install a
new thrust plate.
(4) Line up key with keyway in sprocket, then
using Special Tools C-3688, C-3718 and MB990799
install crankshaft timing sprocket. Make sure the
sprocket seats against the crankshaft shoulder (Fig.
28).
(5) Install timing chain and sprocket (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(6) Install the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(7) Install the crankshaft pulley/damper (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(8) Prime oil pump by squirting oil in the oil filter
mounting hole and filling the J-trap of the front tim-
ing cover. When oil is running out, install oil filter
that has been filled with oil.
(9) Each tappet reused must be installed in the
same position from which it was removed.When
camshaft is replaced, all of the tappets must be
replaced.(10) Install tappets and push rods in their original
location.
(11) Position the tappet aligning yokes and yoke
retaing spider.
(12) Install the retaining spider mounting bolts.
Tighten bolts to 22 N´m (16 ft. lbs.).
(13) Install the rocker arms (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARM / ADJUSTER
ASSY - INSTALLATION).
(14) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.For the
left side the number tab is at the front of
engine with the number up. For the right side
the number tab is at the rear of engine with the
number up.
CAUTION: The cylinder head cover fasteners have a
special plating. DO NOT use alternative fasteners.
(15) Install cylinder head cover (Fig. 29) (Refer to
9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(16) Install the intake manifolds (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
(17) Start engine and check for leaks.
Fig. 28 Crankshaft Sprocket Installation
1 - SPECIAL TOOL C-3688
2 - SPECIAL TOOL C-3718
3 - SPECIAL TOOL MD990799
9 - 86 ENGINE 8.0LBR/BE
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

(6) Prime oil pump by squirting oil in the oil filter
mounting hole and filling the J-trap of the front tim-
ing cover. When oil is running out, install oil filter
that has been filled with oil.
(7) Install water pump and housing assembly
using new o-ring (Refer to 7 - COOLING/ENGINE/
WATER PUMP - INSTALLATION).
(8) Install generator, air pump, and bracket assem-
bly.
(9) Install A/C compressor (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION).
(10) (10) Install the radiator fan (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(11) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(12) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(13) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Connect the negative cable to the battery.
(15) Road test vehicle and check for leaks.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(1) Remove timing chain cover and gasket using
extreme caution to avoid damaging oil pan gasket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL).
(2) Aline camshaft and crankshaft centerline.
Remove camshaft sprocket attaching bolt and remove
timing chain and camshaft sprockets.
(3) Use puller 6444 and jaws 6820 to remove
crankshaft sprocket (Fig. 79).
INSPECTIONÐMEASURING TIMING CHAIN
STRETCH
(1) Place a scale next to the timing chain so that
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam-
shaft sprocket attaching bolt. Apply torque in the
direction of crankshaft rotation to take up slack; 41
N´m (30 ft. lbs.) torque with cylinder head installed
or 20 N´m (15 ft. lbs.) torque with cylinder head
removed. With a torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads
installed, apply 14 N´m (30 ft. lbs.) torque in thereverse direction. With the cylinder heads removed,
apply 20 N´m (15 ft. lbs.) torque in the reverse direc-
tion. Note the amount of chain movement (Fig. 80).
(4) Install a new timing chain, if its movement
exceeds 3.175 mm (1/8 inch).
INSTALLATION
(1) Line up key in crankshaft with keyway in
sprocket, press on crankshaft timing sprocket, use
tools C-3688, C-3718 and MB-990799, seat sprocket
against crankshaft shoulder (Fig. 81).
Fig. 79 Crankshaft Sprocket Removal.
1 - SPECIAL TOOL 6444
2 - SPECIAL TOOL 6820
Fig. 80 Measuring Timing Chain Stretch
1 - TORQUE WRENCH
2 - 3.175 MM
(0.125 IN.)
BR/BEENGINE 8.0L 9 - 111
TIMING BELT / CHAIN COVER(S) (Continued)

incorporates a centrally located high swirl combus-
tion bowl, and utilizes a ªkeystoneº style top com-
pression ring (Fig. 124) , and a ªTapered Faceºintermediate ring (Fig. 124) , for superior cylinder
wall scraping. Piston cooling nozzles cool the piston
and pin with engine oil supplied by the crankshaft
main journals.
The connecting rods (Fig. 125) are a split angle
design constructed of micro alloy. The rods have a
pressed in place wrist pin bushing which is lubri-
cated by the piston cooling nozzle oil spray.
STANDARD PROCEDUREÐPISTON GRADING
²When rebuilding an engine with the original cyl-
inder block, crankshaft and pistons, make sure the
pistons are installed in their original cylinder.
²If replacing the piston(s), make sure the replace-
ment piston(s) are the same grade as the one being
replaced.
²If a new cylinder block and/or crankshaft is
used, the piston grading procedureMUSTbe per-
formed to determine the proper piston grade for each
cylinder.
Fig. 120 Retrieve Tappet Installation Tool through
Cam Bore
Fig. 121 Insert Tool and Pull Tappet Into Place
Fig. 122 Rotate Trough One Half Turn (180É)
Fig. 123 Piston
Fig. 124 Piston Ring Identification
9 - 166 ENGINE 5.9L DIESELBR/BE
PISTON & CONNECTING ROD (Continued)

(7) Position the charge air cooler inlet pipe to the
turbocharger. With the clamp in position, tighten the
clamp nut to 8 N´m (72 in. lbs.) torque.
(8) Position the air inlet hose to the turbocharger
(Fig. 170). Tighten the clamp to 8 N´m (72 in. lbs.)
torque.
(9) Raise vehicle on hoist.
(10) Connect the exhaust pipe to the turbocharger
(Fig. 169) and tighten the bolts to 34 N´m (25 ft. lbs.)
torque.
(11) Lower the vehicle.
(12) Connect the battery negative cables.
(13) Start the engine to check for leaks.
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION
(1) Remove the cylinder head cover.
(2) Remove fuel injector from cylinder number 1.
(3) Remove the crankcase breather from the gear
housing cover.
(4) Using Special Tool 7471B rotate the engine
until the timing mark on the fuel pump gear is
aligned with the TDC mark on the gear housing
cover.
(5) Using a 8 in.x 1/4 in. dowel rod inserted into
cylinder number 1, rock the crankshaft back and
forth to verify piston number 1 is at TDC.
(6) With piston number 1 at TDC the timing mark
on the fuel pump gear should be aligned with the
TDC mark on the gear housing cover. If marks do not
line up, remove the gear housing cover.
(7) With cylinder number still at TDC, inspect the
keyway on the crankshaft gear for proper alignment
(12 o'clock position).
(8) If the keyway is not at 12 o'clock position
replace the crankshaft gear assembly.
(9) If the keyway is at 12 o'clock position, verify
timing mark alignment between the camshaft gear,
crankshaft gear and the fuel pump gear, if not
aligned inspect keyway on camshaft gear.
(10) Inspect keyway on camshaft gear for proper
alignment with the key in the camshaft, if alignment
is off replace the camshaft/gear assembly.
(11) If timing marks alignment is off and no dam-
age is found at either the crankshaft or camshaft
gear keyways, realign timing marks as necessary.
GEAR HOUSING
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.(3) Partially drain engine coolant into container
suitable for re-use (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(4) Lower vehicle.
(5) Remove radiator upper hose.
(6) Disconnect coolant recovery bottle hose from
radiator filler neck and lift bottle off of fan shroud.
(7) Disconnect windshield washer pump supply
hose and electrical connections and lift washer bottle
off of fan shroud.
(8) Remove the fan shroud-to-radiator mounting
bolts.
(9) Remove viscous fan/drive assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(10) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(11) Remove the cooling fan support/hub from the
front of the engine (Fig. 173).
(12) Raise the vehicle on hoist.
(13) Remove the crankshaft damper (Fig. 174)
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(14) Lower the vehicle.
(15) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing (Fig.
175), taking care not to mar the gasket surfaces.
(16) Remove the fuel injection pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - REMOVAL).
(17) Disconnect the camshaft position sensor con-
nector.
Fig. 173 Fan Support/Hub Assembly - Removal/
Installation
1 - FAN SUPPORT/HUB
2 - FAN PULLEY
BR/BEENGINE 5.9L DIESEL 9 - 187
EXHAUST MANIFOLD (Continued)

(4) Connect the 0-414 kPa (0-60 psi) fuel pressure
test gauge (from Gauge Set 5069) to the test port on
the appropriate Adaptor Tool.The DRBtIII Scan
Tool along with the PEP module, the 500 psi
pressure transducer, and the transducer-to-test
port adapter may also be used in place of the
fuel pressure gauge.
The fittings on both tools must be in good
condition and free from any small leaks before
performing the proceeding test.
(5) Start engine and bring to normal operating
temperature.
(6) Observe test gauge. Normal operating pressure
should be 339 kPa +/±34 kPa (49.2 psi +/±5 psi).
(7) Shut engine off.
(8) Pressure should not fall below30 psi for five
minutes.
(9) If pressure falls below 30 psi, it must be deter-
mined if a fuel injector, the check valve within the
fuel pump module, or a fuel tube/line is leaking.
(10) Again, start engine and bring to normal oper-
ating temperature.
(11) Shut engine off.
(12)Testing for fuel injector or fuel rail leak-
age:Clamp off the rubber hose portion of Adaptor
Tool between the fuel rail and the test port ªTº on
Adapter Tool. If pressure now holds at or above 30
psi, a fuel injector or the fuel rail is leaking.
(13)Testing for fuel pump check valve, filter/
regulator check valve or fuel tube/line leakage:
Clamp off the rubber hose portion of Adaptor Tool
between the vehicle fuel line and test port ªTº on
Adapter Tool. If pressure now holds at or above 30
psi, a leak may be found at a fuel tube/line. If no
leaks are found at fuel tubes or lines, one of the
check valves in either the electric fuel pump or filter/
regulator may be leaking.
Note: A quick loss of pressure usually indicates a
defective check valve in the filter/regulator. A slow
loss of pressure usually indicates a defective check
valve in the electric fuel pump.
The electric fuel pump is not serviced separately.
Replace the fuel pump module assembly. The filter/
regulator may be replaced separately on certain
applications. Refer to Fuel Filter/Fuel Pressure Reg-
ulator Removal/Installation for additional informa-
tion.
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fill cap.(2) Remove fuel pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(3) Start and run engine until it stalls.
(4) Attempt restarting engine until it will no
longer run.
(5) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unplug connector from any fuel injector.
(7) Attach one end of a jumper wire with alligator
clips (18 gauge or smaller) to either injector terminal.
(8) Connect other end of jumper wire to positive
side of battery.
(9) Connect one end of a second jumper wire to
remaining injector terminal.
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentarily touch other end of jumper wire
to negative terminal of battery for no more than a
few seconds.
(11) Place a rag or towel below fuel line quick-con-
nect fitting at fuel rail.
(12) Disconnect quick-connect fitting at fuel rail.
Refer to Quick-Connect Fittings.
(13) Return fuel pump relay to PDC.
(14) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRBtscan tool must be
used to erase a DTC.
SPECIFICATIONS
SPECIFICATIONS - FUEL SYSTEM PRESSURE -
GAS ENGINES
All Gasoline Powered Engines:339 kPa   34
kPa (49.2 psi   5 psi)
BR/BEFUEL DELIVERY - GASOLINE 14 - 3
FUEL DELIVERY - GASOLINE (Continued)

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)

WARNING: BEFORE PROCEEDING TO NEXT STEP,
NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI-
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND
FUEL SYSTEM COMPONENTS ARE CONNECTED.
CAUTION: To prevent possible damage to the vehi-
cle electrical system and LCS adapter, the test
leads must be connected into relay cavities exactly
as shown in following steps.
Depending upon vehicle model, year or engine con-
figuration, three different types of relays may be
used: Type-1, type-2 and type±3.
(14) If equipped withtype±1 relay(Fig. 13),
attach test leads from LCS adapter into PDC relay
cavities number 30 and 87. For location of these cav-
ities, refer to numbers stamped to bottom of relay
(Fig. 13).
(15) If equipped withtype±2 relay(Fig. 14),
attach test leads from LCS adapter into PDC relay
cavities number 30 and 87. For location of these cav-
ities, refer to numbers stamped to bottom of relay
(Fig. 14).
(16) If equipped withtype±3 relay(Fig. 15),
attach test leads from LCS adapter into PDC relay
cavities number 3 and 5. For location of these cavi-
ties, refer to numbers stamped to bottom of relay
(Fig. 15).
(17) When LCS adapter test leads are attached
into relay cavities, fuel pumpwill be activated.
Determine fuel pump amperage on DRB screen.
Amperage should be below 10.0 amps. If amperage is
below 10.0 amps, and specifications for the Fuel
Pump Pressure, Fuel Pump Capacity and Fuel Pres-
sure Leak Down tests were met, the fuel pump mod-
ule is OK.
(18) If amperage is more than 10.0 amps, replace
fuel pump module assembly. The electric fuel pump
is not serviced separately.
(19) Disconnect test leads from relay cavities
immediately after testing.
Fig. 13 FUEL PUMP RELAY - TYPE 1
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 14 FUEL PUMP RELAY - TYPE 2
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
BR/BEFUEL DELIVERY - GASOLINE 14 - 11
FUEL PUMP (Continued)