gas tank size DODGE RAM 2003 Service Repair Manual

system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.
5.9L, 5.9L Diesel, and 8.0L engines utilize an
ambient overflow bottle for coolant recovery/reserve.
The 3.7L and 4.7L engines utilize a pressurized
degas bottle for coolant deaeration and reserve. This
degas bottle has coolant flowing through it continu-
ously, supplied by a vent in the hot side radiator
tank and returning to the heater return hose.
An optional factory installed maximum duty cool-
ing package is available on most models. This pack-
age will provide additional cooling capacity for
vehicles used under extreme conditions such as
trailer towing in high ambient temperatures.
OPERATIONÐHOSE CLAMPS
The spring type hose clamp applies constant ten-
sion on a hose connection. To remove a spring type
hose clamp, only use constant tension clamp pliers
designed to compress the hose clamp.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐON-BOARD
DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The Engine Control Module (ECM) has been pro-
grammed to monitor certain cooling system compo-
nents:
²If the engine has remained cool for too long a
period, such as with a stuck open thermostat, a Diag-
nostic Trouble Code (DTC) can be set.²If an open or shorted condition has developed in
the electronically controlled viscous fan clutch circuit,
a Diagnostic Trouble Code (DTC) can be set.
²If fan speed is not detected a DTC will be set.
²Coolant temperature sensor circuit problems can
set a DTC.
If the problem is sensed in a monitored circuit
often enough to indicated an actual problem, a DTC
is stored. The DTC will be stored in the ECM mem-
ory for eventual display to the service technician.
(Refer to 25 - EMISSIONS CONTROL - DESCRIP-
TION).
ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTC's and to obtain cooling system data,
(Refer to 25 - EMISSIONS CONTROL - DESCRIP-
TION).
ERASING TROUBLE CODES
After the problem has been repaired, use the
DRBIIItscan tool to erase a DTC. Refer to the
appropriate Powertrain Diagnostic Procedures ser-
vice information for operation of the DRBIIItscan
tool.
DIAGNOSIS AND TESTINGÐCOOLING SYSTEM
- TESTING FOR LEAKS
ULTRAVIOLET LIGHT METHOD
A leak detection additive is available through the
parts department that can be added to cooling sys-
tem. The additive is highly visible under ultraviolet
light (black light). Pour one ounce of additive into
cooling system. Place heater control unit in HEAT
position. Start and operate the engine until the radi-
ator upper hose is warm to the touch. Aim the com-
mercially available black light tool at the components
to be checked. If leaks are present, the black light
will cause the additive to glow a bright green color.
The black light can be used in conjunction with a
pressure tester to determine if any external leaks
exist (Fig. 5).
PRESSURE TESTER METHOD
The engine should be at normal operating temper-
ature. Recheck the system cold if the cause of coolant
loss is not located during the warm engine examina-
tion.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
Carefully remove the radiator pressure cap from
the filler neck and check the coolant level. Push
down on the cap to disengage it from the stop tabs.
Wipe the inside of the filler neck and examine the
Fig. 4 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
DRCOOLING 7 - 5
COOLING (Continued)

FUEL INJECTOR RAIL - DESCRIPTION....14-89
FUEL INJECTOR RAIL - INSTALLATION....14-90
FUEL INJECTOR RAIL - OPERATION......14-89
FUEL INJECTOR RAIL - REMOVAL.......14-89
FUEL LEVEL SENDING UNIT / SENSOR -
DESCRIPTION...................14-68,14-7
FUEL LEVEL SENDING UNIT / SENSOR -
INSTALLATION........................14-8
FUEL LEVEL SENDING UNIT / SENSOR -
OPERATION.....................14-68,14-7
FUEL LEVEL SENDING UNIT / SENSOR -
REMOVAL...........................14-7
FUEL LINE LEAKS - DIAGNOSIS AND
TESTING, HIGH-PRESSURE.............14-69
FUEL LINES - DESCRIPTION........14-69,14-8
FUEL LINES - INSTALLATION...........14-71
FUEL LINES - OPERATION..............14-69
FUEL LINES - REMOVAL...............14-69
FUEL PRESSURE LIMITING VALVE -
DESCRIPTION.......................14-72
FUEL PRESSURE LIMITING VALVE -
INSTALLATION.......................14-73
FUEL PRESSURE LIMITING VALVE -
OPERATION.........................14-72
FUEL PRESSURE LIMITING VALVE -
REMOVAL..........................14-72
FUEL PRESSURE SENSOR -
DESCRIPTION.......................14-72
FUEL PRESSURE SENSOR -
INSTALLATION.......................14-72
FUEL PRESSURE SENSOR - OPERATION....14-72
FUEL PRESSURE SENSOR - REMOVAL....14-72
FUEL PUMP - DESCRIPTION............14-12
FUEL PUMP - OPERATION.............14-12
FUEL PUMP MODULE - DESCRIPTION....14-12
FUEL PUMP MODULE - INSTALLATION . . . 14-13
FUEL PUMP MODULE - OPERATION......14-12
FUEL PUMP MODULE - REMOVAL.......14-12
FUEL PUMP RELAY - DESCRIPTION......14-33
FUEL PUMP RELAY - INSTALLATION.....14-33
FUEL PUMP RELAY - OPERATION........14-33
FUEL PUMP RELAY - REMOVAL.........14-33
FUEL PUMP RELAYS - DIAGNOSIS AND
TESTING, ASD........................8I-7
FUEL RAIL - DESCRIPTION.............14-13
FUEL RAIL - INSTALLATION............14-18
FUEL RAIL - OPERATION...............14-13
FUEL RAIL - REMOVAL................14-13
FUEL REQUIREMENTS - DIESEL ENGINE
- DESCRIPTION........................0-1
FUEL SENSOR - DESCRIPTION, WATER
IN ................................14-77
FUEL SENSOR - OPERATION, WATER IN . . 14-78
FUEL SENSOR - REMOVAL, WATER IN....14-78
FUEL SYSTEM - DESCRIPTION, DIESEL . . . 14-57
FUEL SYSTEM - TORQUE...............14-3
FUEL SYSTEM PARTS - STANDARD
PROCEDURES, CLEANING..............14-58
FUEL SYSTEM PRESSURE, DIESEL.......14-60
FUEL SYSTEM PRESSURE RELEASE -
STANDARD PROCEDURE................14-2
FUEL SYSTEM PRESSURE,
SPECIFICATIONS......................14-3
FUEL SYSTEM PRIMING - STANDARD
PROCEDURE........................14-59
FUEL SYSTEM, SPECIAL TOOLS..........14-5
FUEL SYSTEM, SPECIAL TOOLS -
DIESEL............................14-60
FUEL TANK - DESCRIPTION............14-20
FUEL TANK - OPERATION..............14-20
FUEL TANK MODULE - DESCRIPTION.....14-75
FUEL TANK MODULE - INSTALLATION....14-75
FUEL TANK MODULE - OPERATION......14-75
FUEL TANK MODULE - REMOVAL........14-75
FUEL TRANSFER PUMP - DESCRIPTION . . 14-75
FUEL TRANSFER PUMP - INSTALLATION . . 14-76
FUEL TRANSFER PUMP - OPERATION....14-76
FUEL TRANSFER PUMP - REMOVAL......14-76
FULL SIZE, SPARE WHEEL WITH
MATCHING TIRE - DESCRIPTION........22-15
FUNCTIONS - DESCRIPTION, CIRCUIT . . 8W-01-6
FUSE - DESCRIPTION, IOD
...........8W-97-6
FUSE - INSTALLATION, IOD
..........8W-97-7
FUSE - OPERATION, IOD
.............8W-97-6
FUSE - REMOVAL, IOD
..............8W-97-6
FUSES POWERING SEVERAL LOADS -
STANDARD PROCEDURE, TESTING
FOR A SHORT TO GROUND ON
......8W-01-10GAP AND FLUSH - SPECIFICATIONS......23-95
GAS - DESCRIPTION, FUEL DELIVERY.....14-1
GAS - INSTALLATION............19-30,19-41
GAS - OPERATION, FUEL DELIVERY.......14-2
GAS - REMOVAL................19-29,19-40
GAS ENGINE - DIAGNOSIS AND TESTING . . 11-2
GAS ENGINE - INSTALLATION...........19-24
GAS ENGINE - REMOVAL..............19-23
GASKET - DESCRIPTION, CYLINDER
HEAD COVER........................9-243
GASKET - DIAGNOSIS AND TESTING,
CYLINDER HEAD......................9-20
GASKET - OPERATION, CYLINDER HEAD
COVER.............................9-243
GASKET FAILURE - DIAGNOSIS AND
TESTING, CYLINDER HEAD . . . 9-194,9-243,9-370
GASKET SELECTION - STANDARD
PROCEDURE, HEAD...................9-330
GASKET SURFACE PREPARATION -
STANDARD PROCEDURE, ENGINE........9-10
GASKETS AND SEALERS - STANDARD
PROCEDURE, FORM-IN-PLACE....9-232,9-289,
9-360,9-9,9-93
GAUGE - DESCRIPTION, ENGINE
TEMPERATURE......................8J-23
GAUGE - DESCRIPTION, FUEL...........8J-25
GAUGE - DESCRIPTION, OIL PRESSURE . . 8J-32
GAUGE - DESCRIPTION, VOLTAGE.......8J-40
GAUGE - OPERATION, ENGINE
TEMPERATURE......................8J-23
GAUGE - OPERATION, FUEL............8J-26
GAUGE - OPERATION, OIL PRESSURE....8J-32
GAUGE - OPERATION, VOLTAGE.........8J-41
GAUGES - DIAGNOSIS AND TESTING,
PRESSURE..........................22-7
GAUGES INDICATOR - DESCRIPTION,
CHECK.............................8J-21
GAUGES INDICATOR - OPERATION,
CHECK.............................8J-21
GEAR - DESCRIPTION, CRANKSHAFT.....9-322
GEAR - INDEPENDENT FRONT
SUSPENSION - DESCRIPTION...........19-16
GEAR - INDEPENDENT FRONT
SUSPENSION - INSTALLATION..........19-17
GEAR - INDEPENDENT FRONT
SUSPENSION - REMOVAL..............19-16
GEAR - INSTALLATION................9-322
GEAR - INSTALLATION, PINION
GEAR/RING......................3-42,3-66
GEAR - LINK/COIL - DESCRIPTION.......19-19
GEAR - LINK/COIL - INSTALLATION......19-20
GEAR - LINK/COIL - OPERATION........19-19
GEAR - LINK/COIL - REMOVAL..........19-19
GEAR - REMOVAL....................9-322
GEAR - REMOVAL, PINION GEAR/RING....3-40,
3-65
GEAR HOUSING - INSTALLATION........9-349
GEAR HOUSING - REMOVAL............9-348
GEAR HOUSING COVER - INSTALLATION . . 9-350
GEAR HOUSING COVER - REMOVAL.....9-349
GEAR INPUT SHAFT SEAL -
INSTALLATION, STEERING.............19-28
GEAR INPUT SHAFT SEAL - REMOVAL,
STEERING..........................19-25
GEAR SELECTOR INDICATOR -
DESCRIPTION.......................8J-26
GEAR SELECTOR INDICATOR -
OPERATION.........................8J-27
GEAR SHIFT LEVER - INSTALLATION.....19-12
GEAR SHIFT LEVER - REMOVAL.........19-12
GEAR, SPECIAL TOOLS - POWER
STEERING..........................19-22
GEAR, SPECIFICATIONS - POWER
STEERING..........................19-21
GEAR TO COOLER - INSTALLATION,
RETURN HOSE.................19-43,19-44
GEAR TO COOLER - REMOVAL, RETURN
HOSE..............................19-43
GEAR/RING GEAR - INSTALLATION,
PINION
.........................3-42,3-66
GEAR/RING GEAR - REMOVAL, PINION
....3-40,
3-65
GEAR/RING GEAR/TONE RING -
INSTALLATION, PINION
.......3-123,3-150,3-96
GEAR/RING GEAR/TONE RING -
REMOVAL, PINION
..........3-122,3-149,3-94
GEARSHIFT CABLE - DIAGNOSIS AND
TESTING
..............21-209,21-389,21-544GEARSHIFT CABLE - INSTALLATION....21-210,
21-390,21-545
GEARSHIFT CABLE - REMOVAL . . 21-209,21-389,
21-544
GEARSHIFT CABLE, ADJUSTMENTS.....21-211,
21-391,21-546
GEAR/TONE RING - INSTALLATION,
PINION GEAR/RING..........3-123,3-150,3-96
GEAR/TONE RING - REMOVAL, PINION
GEAR/RING................3-122,3-149,3-94
GEARTRAIN - ASSEMBLY, PLANETARY . . . 21-573
GEARTRAIN - CLEANING, PLANETARY . . . 21-573
GEARTRAIN - DESCRIPTION,
PLANETARY........................21-571
GEARTRAIN - DISASSEMBLY,
PLANETARY........................21-573
GEARTRAIN - INSPECTION, PLANETARY . 21-573
GEARTRAIN - OPERATION, PLANETARY . . 21-571
GEARTRAIN/OUTPUT SHAFT -
ASSEMBLY, PLANETARY........21-245,21-423
GEARTRAIN/OUTPUT SHAFT -
DESCRIPTION, PLANETARY......21-242,21-420
GEARTRAIN/OUTPUT SHAFT -
DISASSEMBLY, PLANETARY.....21-243,21-421
GEARTRAIN/OUTPUT SHAFT -
INSPECTION, PLANETARY.......21-245,21-422
GEARTRAIN/OUTPUT SHAFT -
OPERATION, PLANETARY.......21-243,21-420
GENERAL - WARNINGS.............8W-01-7
GENERATOR / CHARGING SYSTEM -
SPECIFICATIONS, TORQUE.............8F-20
GENERATOR - DESCRIPTION.............8F-22
GENERATOR - INSTALLATION...........8F-25
GENERATOR - OPERATION.............8F-22
GENERATOR - REMOVAL...............8F-22
GENERATOR RATINGS, SPECIFICATIONS . . 8F-20
GENII - ASSEMBLY, TRANSFER CASE -
NV241............................21-604
GENII - CLEANING, TRANSFER CASE -
NV241............................21-602
GENII - DESCRIPTION, TRANSFER CASE
- NV241..............................0-4
GENII - DESCRIPTION, TRANSFER CASE
- NV241...........................21-591
GENII - DIAGNOSIS AND TESTING,
TRANSFER CASE - NV241.............21-592
GENII - DISASSEMBLY, TRANSFER CASE
- NV241...........................21-593
GENII - INSPECTION, TRANSFER CASE -
NV241............................21-602
GENII - INSTALLATION, TRANSFER CASE
- NV241...........................21-614
GENII - OPERATION, TRANSFER CASE -
NV241............................21-591
GENII - REMOVAL, TRANSFER CASE -
NV241............................21-593
GENII - TRANSFER CASE, NV241.......21-614
GLASS - INSTALLATION, BACKLITE VENT . 23-87
GLASS - INSTALLATION, DOOR....23-20,23-30
GLASS - INSTALLATION, SIDE VIEW
MIRROR...........................23-44
GLASS - REMOVAL, BACKLITE VENT.....23-87
GLASS - REMOVAL, DOOR........23-20,23-30
GLASS - REMOVAL, SIDE VIEW MIRROR . . 23-42
GLASS RUN CHANNEL - INSTALLATION . . 23-21,
23-31
GLASS RUN CHANNEL - REMOVAL . 23-21,23-30
GLASS RUN WEATHERSTRIP -
INSTALLATION, FRONT DOOR...........23-92
GLASS RUN WEATHERSTRIP -
INSTALLATION, REAR DOOR............23-93
GLASS RUN WEATHERSTRIP -
REMOVAL, FRONT DOOR..............23-92
GLASS RUN WEATHERSTRIP -
REMOVAL, REAR DOOR...............23-93
GLOVE BOX - INSTALLATION...........23-53
GLOVE BOX - REMOVAL...............23-53
GLOVE BOX LAMP/SWITCH -
INSTALLATION.......................8L-25
GLOVE BOX LAMP/SWITCH - REMOVAL . . . 8L-25
GLOVE BOX LATCH - INSTALLATION
.....23-53
GLOVE BOX LATCH - REMOVAL
.........23-53
GOVERNOR - DESCRIPTION,
ELECTRONIC
.................21-196,21-376
GOVERNOR - INSTALLATION,
ELECTRONIC
.................21-199,21-379
GOVERNOR - OPERATION, ELECTRONIC
. 21-196,
21-377
DRINDEX 15
Description Group-Page Description Group-Page Description Group-Page