2001 DODGE RAM check engine

tion on the high-line or premium CTM. (Refer to 8 -
ELECTRICAL/VEHICLE THEFT SECURITY - GEN-
ERAL INFORMATION) for more information on the
VTSS. (Refer to 8 - ELECTRICAL/POWER LOCKS -
GENERAL INFORMATION) for more information on
the RKE system.
HORN
DESCRIPTION
The standard single, low-note, electromagnetic dia-
phragm-type horn is secured with a bracket to the
right front fender wheel house extension in the
engine compartment. The high-note horn for the
optional dual-note horn system is connected in paral-
lel with and secured with a bracket just forward of
the low-note horn. Each horn is grounded through its
wire harness connector and circuit to a ground splice
joint connector, and receives battery feed through the
closed contacts of the horn relay.
The horns cannot be repaired or adjusted and, if
faulty or damaged, they must be individually replaced.
OPERATION
Within the two halves of the molded plastic horn
housing are a flexible diaphragm, a plunger, an elec-
tromagnetic coil and a set of contact points. The dia-
phragm is secured in suspension around its
perimeter by the mating surfaces of the horn hous-
ing. The plunger is secured to the center of the dia-
phragm and extends into the center of the
electromagnet. The contact points control the current
flow through the electromagnet.
When the horn is energized, electrical current
flows through the closed contact points to the electro-
magnet. The resulting electromagnetic field draws
the plunger and diaphragm toward it until that
movement mechanically opens the contact points.
When the contact points open, the electromagnetic
field collapses allowing the plunger and diaphragm to
return to their relaxed positions and closing the con-
tact points again. This cycle continues repeating at a
very rapid rate producing the vibration and move-
ment of air that creates the sound that is directed
through the horn outlet.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HORN
For complete circuit diagrams, refer to the appro-
priate wiring information. The wiring information
includes wiring diagrams, proper wire and connector
repair procedures, details of wire harness routing
and retention, connector pin-out information andlocation views for the various wire harness connec-
tors, splices and grounds.
(1) Disconnect the wire harness connector(s) from
the horn connector receptacle(s). Measure the resis-
tance between the ground circuit cavity of the horn(s)
wire harness connector(s) and a good ground. There
should be no measurable resistance. If OK, go to Step
2. If not OK, repair the open ground circuit to ground
as required.
(2) Check for battery voltage at the horn relay out-
put circuit cavity of the horn(s) wire harness connec-
tor(s). There should be zero volts. If OK, go to Step 3.
If not OK, repair the shorted horn relay output cir-
cuit or replace the faulty horn relay as required.
(3) Depress the horn switch. There should now be
battery voltage at the horn relay output circuit cavity
of the horn(s) wire harness connector(s). If OK,
replace the faulty horn(s). If not OK, repair the open
horn relay output circuit to the horn relay as
required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Disconnect the wire harness connector(s) from
the horn connector receptacle(s) (Fig. 1) .
(3) Remove the screw that secures the horn and
mounting bracket unit(s) to the right fender wheel
house front extension.
(4) Remove the horn and mounting bracket unit(s)
from the right fender wheel house front extension.
Fig. 1 Horns Remove/Install
1 - WIRE HARNESS CONNECTOR
2 - SCREWS
3 - INNER FENDER
4 - LOW NOTE HORN
5 - WIRE HARNESS CONNECTOR
6 - WHEELHOUSE EXTENSION
7 - HIGH NOTE HORN
8H - 2 HORNBR/BE
HORN (Continued)

REMOVAL - 8.0L
The camshaft position sensor is located on the tim-
ing chain case/cover on the left-front side of the
engine (Fig. 12).
A thin plastic rib is molded into the face of the sen-
sor (Fig. 13) to position the depth of sensor to the
upper cam gear (sprocket). This rib can be found on
both the new replacement sensors and sensors that
were originally installed to the engine. The first time
the engine has been operated, part of this rib may be
sheared (ground) off. Depending on parts tolerances,
some of the rib material may still be observed after
removal.Refer to either of the following procedures; Replac-
ing Old Sensor With Original, or Replacing With
New Sensor:
REPLACING OLD SENSOR WITH ORIGINAL
If the original camshaft position sensor is to be
removed and installed, such as when servicing the
timing chain, timing gears or timing chain cover, use
this procedure.
(1) Disconnect the sensor harness connector from
the sensor.
(2) Remove the sensor mounting bolt (Fig. 12).
(3) Carefully pry the sensor from the timing chain
case/cover in a rocking action with two small screw-
drivers.
(4) Remove the sensor from vehicle.
(5) Check condition of sensor o-ring (Fig. 14).
REPLACING WITH NEW SENSOR
If a new replacement camshaft position sensor is to
be installed, use this procedure.
(1) Disconnect the sensor wiring harness connector
from sensor.
(2) Remove the sensor mounting bolt (Fig. 12).
(3) Carefully pry the sensor from the timing chain
case/cover in a rocking action with two small screw-
drivers.
(4) Remove the sensor from vehicle.
INSTALLATION - DIESEL
The camshaft position sensor (CMP) is located
below the fuel injection pump (Fig. 9). It is attached
to the back of the timing gear cover housing.
(1) Install new o-ring to CMP. Apply clean engine
oil to o-ring.
Fig. 11 Camshaft Position SensorÐTypical
1 - SYNC SIGNAL GENERATOR
2 - CAMSHAFT POSITION SENSOR
3 - PULSE RING
4 - DISTRIBUTOR ASSEMBLY
Fig. 12 CMP Location - 8.0L
1 - CAMSHAFT POSITION SENSOR
2 - MOUNTING BOLT
3 - TIMING CHAIN CASE/COVER
Fig. 13 Sensor Depth Positioning RibÐ8.0L V-10
Engine
1 - CAMSHAFT POSITION SENSOR
2 - PAPER SPACER
3 - RIB MATERIAL (FOR SENSOR DEPTH POSITIONING)
8I - 8 IGNITION CONTROLBR/BE
CAMSHAFT POSITION SENSOR (Continued)

removed). Then continue to slowly rotate engine
clockwise until indicating mark (Fig. 18) is aligned to
0 degree (TDC) mark on timing chain cover.
(1) Clean top of cylinder block for a good seal
between distributor base and block.
(2) Lightly oil the rubber o-ring seal on the distrib-
utor housing.
(3) Install rotor to distributor shaft.
(4) Position distributor into engine to its original
position. Engage tongue of distributor shaft with slot
in distributor oil pump drive gear. Position rotor to
the number one spark plug cable position.
(5) Install distributor holddown clamp and clamp
bolt. Do not tighten bolt at this time.(6) Rotate the distributor housing until rotor is
aligned to CYL. NO. 1 alignment mark on the cam-
shaft position sensor (Fig. 19) .
(7) Tighten clamp holddown bolt (Fig. 20) to 22.5
N´m (200 in. lbs.) torque.
(8) Connect camshaft position sensor wiring har-
ness to main engine harness.
(9) Install distributor cap. Tighten mounting
screws.
(10) Refer to the following, Checking Distributor
Position.
Checking Distributor Position
To verify correct distributor rotational position, the
DRB scan tool must be used.
WARNING: WHEN PERFORMING THE FOLLOWING
TEST, THE ENGINE WILL BE RUNNING. BE CARE-
FUL NOT TO STAND IN LINE WITH THE FAN
BLADES OR FAN BELT. DO NOT WEAR LOOSE
CLOTHING.
(1) Connect DRB scan tool to data link connector.
The data link connector is located in passenger com-
partment, below and to left of steering column.
(2) Gain access to SET SYNC screen on DRB.
(3) Follow directions on DRB screen and start
engine. Bring to operating temperature (engine must
be in ªclosed loopº mode).
(4) With engine running atidle speed, the words
IN RANGE should appear on screen along with 0É.
This indicates correct distributor position.
(5) If a plus (+) or a minus (-) is displayed next to
degree number, and/or the degree displayed is not
zero, loosen but do not remove distributor holddown
clamp bolt. Rotate distributor until IN RANGE
appears on screen. Continue to rotate distributor
until achieving as close to 0É as possible. After
adjustment, tighten clamp bolt to 22.5 N´m (200 in.
lbs.) torque.
The degree scale on SET SYNC screen of DRB is
referring to fuel synchronization only.It is not
referring to ignition timing.Because of this, do
not attempt to adjust ignition timing using this
method. Rotating distributor will have no effect on
ignition timing. All ignition timing values are con-
trolled by powertrain control module (PCM).
After testing, install air cleaner assembly.
DISTRIBUTOR CAP
DIAGNOSIS AND TESTING - DISTRIBUTOR
CAP
Remove the distributor cap and wipe it clean with
a dry lint free cloth. Visually inspect the cap for
cracks, carbon paths, broken towers or damaged
Fig. 19 Rotor Alignment Mark
1 - CAMSHAFT POSITION SENSOR ALIGNMENT MARK
2 - ROTOR
3 - DISTRIBUTOR
Fig. 20 Distributor Holddown Clamp
1 - CLAMP BOLT
2 - HOLDDOWN CLAMP
3 - DISTRIBUTOR HOUSING
8I - 12 IGNITION CONTROLBR/BE
DISTRIBUTOR (Continued)

rotor button (Fig. 21) or (Fig. 22). Also check for
white deposits on the inside (caused by condensation
entering the cap through cracks). Replace any cap
that displays charred or eroded terminals. The
machined surface of a terminal end (faces toward
rotor) will indicate some evidence of erosion from
normal operation. Examine the terminal ends for evi-
dence of mechanical interference with the rotor tip.DISTRIBUTOR ROTOR
DIAGNOSIS AND TESTING - DISTRIBUTOR
ROTOR
Visually inspect the rotor (Fig. 23) for cracks, evi-
dence of corrosion or the effects of arcing on the
metal tip. Also check for evidence of mechanical
interference with the cap. Some charring is normal
on the end of the metal tip. The silicone-dielectric-
varnish-compound applied to the rotor tip for radio
interference noise suppression, will appear charred.
This is normal.Do not remove the charred com-
pound.Test the spring for insufficient tension.
Replace a rotor that displays any of these adverse
conditions.
IGNITION COIL
DESCRIPTION - 3.9L/5.2L/5.9L
A single ignition coil is used. The coil is not oil
filled. The coil windings are embedded in an epoxy
compound. This provides heat and vibration resis-
tance that allows the coil to be mounted on the
engine.
DESCRIPTION - 8.0L
Two separate coil packs containing a total of five
independent coils are attached to a common mount-
ing bracket. They are located above the right engine
valve cover (Fig. 24). The coil packs are not oil filled.
The front coil pack contains three independent epoxy
Fig. 21 Cap InspectionÐExternalÐTypical
1 - BROKEN TOWER
2 - DISTRIBUTOR CAP
3 - CARBON PATH
4 - CRACK
Fig. 22 Cap InspectionÐInternalÐTypical
1 - CHARRED OR ERODED TERMINALS
2 - WORN OR DAMAGED ROTOR BUTTON
3 - CARBON PATH
Fig. 23 Rotor InspectionÐTypical
1 - INSUFFICIENT SPRING TENSION
2 - CRACKS
3 - EVIDENCE OF PHYSICAL CONTACT WITH CAP
4 - ROTOR TIP CORRODED
BR/BEIGNITION CONTROL 8I - 13
DISTRIBUTOR CAP (Continued)

SPARK PLUG
DESCRIPTION
The 3.9L V-6 and 5.2L/5.9L V-8 engines use resis-
tor type spark plugs. The 8.0L V-10 engine uses
inductive type spark plugs.
Spark plug resistance values range from 6,000 to
20,000 ohms (when checked with at least a 1000 volt
spark plug tester).Do not use an ohmmeter to
check the resistance values of the spark plugs.
Inaccurate readings will result.
OPERATION
To prevent possible pre-ignition and/or mechanical
engine damage, the correct type/heat range/number
spark plug must be used.
Always use the recommended torque when tighten-
ing spark plugs. Incorrect torque can distort the
spark plug and change plug gap. It can also pull the
plug threads and do possible damage to both the
spark plug and the cylinder head.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. A sin-gle plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Replace spark plugs at the intervals recommended in
Group O, Lubrication and Maintenance
Spark plugs that have low mileage may be cleaned
and reused if not otherwise defective, carbon or oil
fouled. Also refer to Spark Plug Conditions.
CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator and will cause
plug misfire.
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS
NORMAL OPERATING
The few deposits present on the spark plug will
probably be light tan or slightly gray in color. This is
evident with most grades of commercial gasoline
(Fig. 29). There will not be evidence of electrode
burning. Gap growth will not average more than
approximately 0.025 mm (.001 in) per 3200 km (2000
miles) of operation. Spark plugs that have normal
wear can usually be cleaned, have the electrodes
filed, have the gap set and then be installed.
Some fuel refiners in several areas of the United
States have introduced a manganese additive (MMT)
for unleaded fuel. During combustion, fuel with MMT
causes the entire tip of the spark plug to be coated
with a rust colored deposit. This rust color can be
misdiagnosed as being caused by coolant in the com-
bustion chamber. Spark plug performance may be
affected by MMT deposits.
Fig. 28 Spark Plug Cable OrderÐ8.0L V-10 Engine
Fig. 29 Normal Operation and Cold (Carbon) Fouling
1 - NORMAL
2 - DRY BLACK DEPOSITS
3 - COLD (CARBON) FOULING
8I - 16 IGNITION CONTROLBR/BE
IGNITION COIL (Continued)

CLEANING
The plugs may be cleaned using commercially
available spark plug cleaning equipment. After clean-
ing, file center electrode flat with a small point file or
jewelers file before adjusting gap.
CAUTION: Never use a motorized wire wheel brush
to clean spark plugs. Metallic deposits will remain
on spark plug insulator and will cause plug misfire.
INSTALLATION
Special care should be taken when installing spark
plugs into the cylinder head spark plug wells. Be
sure the plugs do not drop into the plug wells as elec-
trodes can be damaged.
Always tighten spark plugs to the specified torque.
Over tightening can cause distortion resulting in a
change in the spark plug gap or a cracked porcelain
insulator.
When replacing the spark plug and ignition coil
cables, route the cables correctly and secure them in
the appropriate retainers. Failure to route the cables
properly can cause the radio to reproduce ignition
noise. It could cause cross ignition of the spark plugs
or short circuit the cables to ground.
(1) Start the spark plug into the cylinder head by
hand to avoid cross threading.
(2) Tighten spark plugs to 35-41 N´m (26-30 ft.
lbs.) torque.
(3) Install spark plug cables over spark plugs.
SPARK PLUG CABLE
DESCRIPTION
Spark plug cables are sometimes referred to as sec-
ondary ignition wires.
OPERATION
The spark plug cables transfer electrical current
from the ignition coil(s) and/or distributor, to individ-
ual spark plugs at each cylinder. The resistive spark
plug cables are of nonmetallic construction. The
cables provide suppression of radio frequency emis-
sions from the ignition system.
DIAGNOSIS AND TESTING - SPARK PLUG
CABLES
Cable routing is important on certain engines. To
prevent possible ignition crossfire, be sure the cables
are clipped into the plastic routing looms. Try to pre-
vent any one cable from contacting another. Before
removing cables, note their original location and
routing. Never allow one cable to be twisted around
another.
Check the spark plug cable connections for good
contact at the coil(s), distributor cap towers, and
spark plugs. Terminals should be fully seated. The
insulators should be in good condition and should fit
tightly on the coil, distributor and spark plugs. Spark
plug cables with insulators that are cracked or torn
must be replaced.
Clean high voltage ignition cables with a cloth
moistened with a non-flammable solvent. Wipe the
cables dry. Check for brittle or cracked insulation.
On 3.9L/5.2L/5.9L engines, spark plug cable heat
shields are pressed into the cylinder head to sur-
round each spark plug cable boot and spark plug
(Fig. 37). These shields protect the spark plug boots
from damage (due to intense engine heat generated
by the exhaust manifolds) and should not be
removed. After the spark plug cable has been
installed, the lip of the cable boot should have a
small air gap to the top of the heat shield (Fig. 37).
TESTING
When testing secondary cables for damage with an
oscilloscope, follow the instructions of the equipment
manufacturer.
If an oscilloscope is not available, spark plug cables
may be tested as follows:
CAUTION: Do not leave any one spark plug cable
disconnected for longer than necessary during test-
ing. This may cause possible heat damage to the
catalytic converter. Total test time must not exceed
ten minutes.
Fig. 36 Heat ShieldsÐ3.9L/5.2L/5.9L Engines
1 - AIR GAP
2 - SPARK PLUG BOOT HEAT SHIELD
BR/BEIGNITION CONTROL 8I - 19
SPARK PLUG (Continued)

With the engine running, remove spark plug cable
from spark plug (one at a time) and hold next to a
good engine ground. If the cable and spark plug are
in good condition, the engine rpm should drop and
the engine will run poorly. If engine rpm does not
drop, the cable and/or spark plug may not be operat-
ing properly and should be replaced. Also check
engine cylinder compression.
With the engine not running, connect one end of a
test probe to a good ground. Start the engine and run
the other end of the test probe along the entire
length of all spark plug cables. If cables are cracked
or punctured, there will be a noticeable spark jump
from the damaged area to the test probe. The cable
running from the ignition coil to the distributor cap
can be checked in the same manner. Cracked, dam-
aged or faulty cables should be replaced with resis-
tance type cable. This can be identified by the words
ELECTRONIC SUPPRESSION printed on the cable
jacket.
Use an ohmmeter to test for open circuits, exces-
sive resistance or loose terminals. If equipped,
remove the distributor cap from the distributor.Do
not remove cables from cap.Remove cable from
spark plug. Connect ohmmeter to spark plug termi-
nal end of cable and to corresponding electrode in
distributor cap. Resistance should be 250 to 1000
Ohms per inch of cable. If not, remove cable from dis-
tributor cap tower and connect ohmmeter to the ter-
minal ends of cable. If resistance is not within
specifications as found in the SPARK PLUG CABLE
RESISTANCE chart, replace the cable. Test all spark
plug cables in this manner.
SPARK PLUG CABLE RESISTANCE
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
To test ignition coil-to-distributor cap cable, do not
remove the cable from the cap. Connect ohmmeter to
rotor button (center contact) of distributor cap and
terminal at ignition coil end of cable. If resistance is
not within specifications as found in the Spark Plug
Cable Resistance chart, remove the cable from the
distributor cap. Connect the ohmmeter to the termi-
nal ends of the cable. If resistance is not within spec-
ifications as found in the Spark Plug Cable
Resistance chart, replace the cable. Inspect the igni-
tion coil tower for cracks, burns or corrosion.
REMOVAL
CAUTION: When disconnecting a high voltage cable
from a spark plug or from the distributor cap, twist
the rubber boot slightly (1/2 turn) to break it loose
(Fig. 38). Grasp the boot (not the cable) and pull it
off with a steady, even force.
INSTALLATION
Install cables into the proper engine cylinder firing
order (Fig. 39), (Fig. 40) or (Fig. 41).
When replacing the spark plug and coil cables,
route the cables correctly and secure in the proper
retainers. Failure to route the cables properly can
cause the radio to reproduce ignition noise. It could
also cause cross ignition of the plugs or short circuit
the cables to ground.
Fig. 37 Heat ShieldsÐ3.9L/5.2L/5.9L Engines
1 - AIR GAP
2 - SPARK PLUG BOOT HEAT SHIELD
Fig. 38 Cable Removal
1 - SPARK PLUG CABLE AND BOOT
2 - SPARK PLUG BOOT PULLER
3 - TWIST AND PULL
4 - SPARK PLUG
8I - 20 IGNITION CONTROLBR/BE
SPARK PLUG CABLE (Continued)

INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION............................2
OPERATION.............................3
DIAGNOSIS AND TESTING..................6
INSTRUMENT CLUSTER..................6
REMOVAL..............................10
DISASSEMBLY...........................11
ASSEMBLY.............................13
INSTALLATION...........................14
ABS INDICATOR
DESCRIPTION...........................14
OPERATION.............................14
AIRBAG INDICATOR
DESCRIPTION...........................15
OPERATION.............................15
BRAKE/PARK BRAKE INDICATOR
DESCRIPTION...........................16
OPERATION.............................16
DIAGNOSIS AND TESTING.................16
BRAKE INDICATOR.....................16
CHECK GAUGES INDICATOR
DESCRIPTION...........................17
OPERATION.............................17
CRUISE INDICATOR
DESCRIPTION...........................18
OPERATION.............................18
ENGINE TEMPERATURE GAUGE
DESCRIPTION...........................19
OPERATION.............................19
FUEL GAUGE
DESCRIPTION...........................20
OPERATION.............................20
GEAR SELECTOR INDICATOR
DESCRIPTION...........................21
OPERATION.............................21
HIGH BEAM INDICATOR
DESCRIPTION...........................21
OPERATION.............................22
DIAGNOSIS AND TESTING.................22
HIGH BEAM INDICATOR.................22
LOW FUEL INDICATOR
DESCRIPTION...........................23
OPERATION.............................23
MALFUNCTION INDICATOR LAMP (MIL)
DESCRIPTION...........................24
OPERATION.............................24
ODOMETER
DESCRIPTION...........................24
OPERATION.............................25OIL PRESSURE GAUGE
DESCRIPTION...........................25
OPERATION.............................26
OVERDRIVE OFF INDICATOR
DESCRIPTION...........................27
OPERATION.............................27
SEATBELT INDICATOR
DESCRIPTION...........................27
OPERATION.............................27
SERVICE REMINDER INDICATOR
DESCRIPTION...........................28
OPERATION.............................28
SHIFT INDICATOR (TRANSFER CASE)
DESCRIPTION...........................29
OPERATION.............................29
DIAGNOSIS AND TESTING.................29
FOUR-WHEEL DRIVE INDICATOR..........29
SPEEDOMETER
DESCRIPTION...........................30
OPERATION.............................30
TACHOMETER
DESCRIPTION...........................30
OPERATION.............................31
TRANSMISSION OVERTEMP INDICATOR
DESCRIPTION...........................31
OPERATION.............................31
TURN SIGNAL INDICATORS
DESCRIPTION...........................32
OPERATION.............................32
DIAGNOSIS AND TESTING.................32
TURN SIGNAL INDICATORS..............32
UPSHIFT INDICATOR
DESCRIPTION...........................33
OPERATION.............................33
VOLTAGE GAUGE
DESCRIPTION...........................33
OPERATION.............................34
WAIT-TO-START INDICATOR
DESCRIPTION...........................34
OPERATION.............................35
WASHER FLUID INDICATOR
DESCRIPTION...........................35
OPERATION.............................35
DIAGNOSIS AND TESTING.................36
WASHER FLUID INDICATOR..............36
WATER-IN-FUEL INDICATOR
DESCRIPTION...........................36
OPERATION.............................37
BR/BEINSTRUMENT CLUSTER 8J - 1