2002 DODGE RAM PCM

FUEL INJECTION - DIESEL
TABLE OF CONTENTS
page page
FUEL INJECTION - DIESEL
DESCRIPTION - DIESEL FUEL INJECTION
SYSTEM............................91
DIAGNOSIS AND TESTING - BOOST
PRESSURE..........................93
SPECIFICATIONS
TORQUE - DIESEL ENGINE.............94
ACCELERATOR PEDAL POSITION SENSOR
DESCRIPTION.........................95
OPERATION...........................95
REMOVAL.............................95
INSTALLATION.........................97
FUEL INJECTOR
DESCRIPTION.........................97
OPERATION...........................98
DIAGNOSIS AND TESTINGÐFUEL INJECTOR
TEST...............................99
REMOVAL............................101
INSTALLATION........................102
FUEL INJECTION PUMP RELAY
DESCRIPTION........................103
OPERATION..........................103
FUEL TEMPERATURE SENSOR
DESCRIPTION........................104
OPERATION..........................104
INTAKE AIR HEATER
DESCRIPTION........................104OPERATION..........................104
REMOVAL............................104
INSTALLATION........................105
INTAKE AIR HEATER RELAY
DESCRIPTION........................105
OPERATION..........................105
REMOVAL............................106
INSTALLATION........................106
INTAKE AIR TEMPERATURE SENSOR
DESCRIPTION - DIESEL.................106
OPERATION - DIESEL..................106
REMOVAL - DIESEL....................107
INSTALLATION - DIESEL................107
MAP SENSOR
DESCRIPTION - DIESEL.................108
OPERATION - DIESEL..................108
REMOVAL - DIESEL....................108
INSTALLATION........................108
PTO SWITCH
DESCRIPTION
OPERATION........................108
THROTTLE CONTROL CABLE
REMOVAL............................109
INSTALLATION........................110
FUEL INJECTION - DIESEL
DESCRIPTION - DIESEL FUEL INJECTION
SYSTEM
The Engine Control Module (ECM) and Fuel Injec-
tion Pump Control Module (FPCM) are used prima-
rily for fuel system control. The ECM is a separate
replaceable component, while the FPCM is internal
to the fuel injection pump and is a non-serviceable
part. The ECM and FPCM are interconnected (wired
together) for fuel injection control.The Powertrain Control Module (PCM) is used to
regulate or control the A/C, charging and speed con-
trol systems. It is also used to partially control cer-
tain electronic automatic transmission components.
The PCM also has control over certain instrument
panel components.
Refer to either Powertrain Control Module (PCM)
or Engine Control Module (ECM) for additional infor-
mation. Refer to (Fig. 1) for a partial list of fuel sys-
tem components.
BR/BEFUEL INJECTION - DIESEL 14 - 91

SPECIFICATIONS
TORQUE - DIESEL ENGINE
DESCRIPTION N m Ft. Lbs. In. Lbs.
Accelerator Pedal Position Sensor Bracket Bolts 12 9 105
Air Intake Housing Bolts 24 18 212
Banjo Fittings at top of Filter/Separator 24 18 212
Banjo Fittings at Fuel Return Lines 24 18 212
Banjo Fitting At Fuel Supply Line (Injector Pump) 24 18 212
Camshaft Position Sensor (CMP) Bolt 20 15 177
ECM Mounting Bolts 24 18 212
Engine Coolant Temperature (ECT) Sensor 14 10 124
Engine Lifting Bracket Bolts 77 57 681
Fuel Drain Manifold ªTº Fitting 12 9 106
Fuel Filter Canister Bracket Bolts 24 18 212
Fuel Filter Canister Mounting Nut 14 10 124
Fuel Filter Drain Valve Mounting Screws 3-5 2-4 30-40
Fuel Heater Screws 2-3 1-2 15-20
Fuel Injector Clamp Bolts 10 7 89
Fuel Pump Module Locknut 24-44 18-32 212-389
Fuel Tank Mounting Nuts 41 30 363
Fuel Transfer Pump Mounting Nuts 12 9 106
High-Pressure Fuel Line Fittings (at Injectors) 38 28 336
High-Pressure Fuel Line Fittings (at Pump) 24 18 212
High-Pressure Fuel Line Clamps-to-Intake Manifold 24 18 212
Hose Clamps at Intercooler Tube 8 6 72
Injection Pump-to-Injection Pump Gear Nut 170 125
Injection Pump Mounting Nuts 43 32 380
Intake Manifold Air Temperature (IAT) Sensor 14 10
Intake Manifold Air Heater Relay Bolts 4.5 40
Manifold Air Pressure (MAP) Sensor 14 10
PCM Mounting Bolts 4 35
Overflow Valve-to-Fuel Injection Pump 24 18
Water-In-Fuel (WIF) Sensor 2-3 15-20
14 - 94 FUEL INJECTION - DIESELBR/BE
FUEL INJECTION - DIESEL (Continued)

(1) Disconnect both negative battery cables at both
batteries.
(2) Remove cable cover (Fig. 6). Cable cover is
attached with 2 Phillips screws, 2 plastic retention
clips and 2 push tabs (Fig. 6). Remove 2 Phillips
screws and carefully pry out 2 retention clips. After
clip removal, push rearward on front tab, and
upward on lower tab for cover removal.
(3) Using finger pressure only, disconnect end of
speed control servo cable from throttle lever pin by
pulling forward on connector while holding lever
rearward (Fig. 7).DO NOT try to pull connector
off perpendicular to lever pin. Connector will
be broken.
(4) Using two small screwdrivers, pry throttle
cable connector socket from throttle lever ball (Fig.
7).Be very careful not to bend throttle lever
arm.
(5) Disconnect transmission control cable at lever
arm (if equipped). Refer to 21, Transmission.
(6) Squeeze pinch tabs on speed control cable (Fig.
7) and pull cable rearward to remove from cable
mounting bracket.
(7) Squeeze pinch tabs on throttle cable (Fig. 7)
and pull cable rearward to remove from cable mount-
ing bracket.
(8) If equipped with an automatic transmission,
refer to 21, Transmission for transmission control
cable removal procedures.
(9) Disconnect wiring harness clip (Fig. 8) at bot-
tom of bracket.
(10) Remove 6 mounting bolts (Fig. 8) and par-
tially remove APPS assembly from engine. After
assembly is partially removed, disconnect electrical
connector from bottom of sensor by pushing on con-
nector tab (Fig. 9).
(11) Remove APPS assembly from engine.
INSTALLATION
The APPS is serviced (replaced) as one assembly
including the lever, brackets and sensor. The APPS is
calibrated to its mounting bracket. The APPS assem-
bly is located at left-front of engine below plastic
cable/lever/linkage cover (Fig. 6) .
(1) Snap electrical connector into bottom of sensor.
(2) Position APPS assembly to engine and install 6
bolts. Tighten bolts to 12 N´m (105 in. lbs.) torque.
(3) Connect wiring harness clip (Fig. 8) at bottom
of bracket.
(4) If equipped with an automatic transmission,
refer to Group 21, Transmission for transmission con-
trol cable installation procedures.
(5) Install speed control cable into mounting
bracket. Be sure pinch tabs (Fig. 7) have secured
cable.(6) Install throttle cable into mounting bracket. Be
sure pinch tabs (Fig. 7) have secured cable.
(7) Connect throttle cable at lever (snaps on).
(8) Connect speed control cable to lever by pushing
cable connector rearward onto lever pin while hold-
ing lever forward.
(9) Install cable cover.
(10) Connect both negative battery cables to both
batteries.
(11)ECM Calibration:Turn key to ON position.
Without starting engine, slowly press throttle pedal
to floor and then slowly release. This step must be
done (one time) to ensure accelerator pedal position
sensor calibration has been learned by ECM. If not
done, possible DTC's may be set.
(12) Use DRB scan tool to erase any DTC's from
ECM/PCM.
FUEL INJECTOR
DESCRIPTION
Six individual, high-pressure fuel injectors are
used. The injectors are vertically mounted (Fig. 10)
into a bored hole in the top of the cylinder head. This
bored hole is located between the intake/exhaust
valves.
Fig. 10 Fuel Injector Location
1 - CLAMP
2 - FUEL INJECTOR
3 - BORED HOLE
4 - SHIM
5 - BOLTS
BR/BEFUEL INJECTION - DIESEL 14 - 97
ACCELERATOR PEDAL POSITION SENSOR (Continued)

IDENTIFICATION
Transmission identification numbers are stamped
on the left side of the case just above the oil pan gas-
ket surface (Fig. 2). Refer to this information when
ordering replacement parts.
GEAR RATIOS
The 46RE gear ratios are:
1st.................................2.45:1
2nd................................1.45:1
3rd.................................1.00:1
4th.................................0.69:1
Rev..................................2.21
OPERATION
The application of each driving or holding compo-
nent is controlled by the valve body based upon the
manual lever position, throttle pressure, and gover-
nor pressure. The governor pressure is a variable
pressure input to the valve body and is one of the
signals that a shift is necessary. First through fourth
gear are obtained by selectively applying and releas-
ing the different clutches and bands. Engine power is
thereby routed to the various planetary gear assem-
blies which combine with the overrunning clutch
assemblies to generate the different gear ratios. The
torque converter clutch is hydraulically applied and
is released when fluid is vented from the hydraulic
circuit by the torque converter control (TCC) solenoid
on the valve body. The torque converter clutch is con-
trolled by the Powertrain Control Module (PCM). The
torque converter clutch engages in fourth gear, and
in third gear under various conditions, such as when
the O/D switch is OFF, when the vehicle is cruising
on a level surface after the vehicle has warmed up.
The torque converter clutch will disengage momen-
tarily when an increase in engine load is sensed by
the PCM, such as when the vehicle begins to go
uphill or the throttle pressure is increased. The
torque converter clutch feature increases fuel econ-
omy and reduces the transmission fluid temperature.
Since the overdrive clutch is applied in fourth gear
only and the direct clutch is applied in all ranges
except fourth gear, the transmission operation for
park, neutral, and first through third gear will be
described first. Once these powerflows are described,
the third to fourth shift sequence will be described.
1 - TORQUE CONVERTER 11 - DIRECT CLUTCH
2 - INPUT SHAFT 12 - PLANETARY GEAR
3 - OIL PUMP 13 - OUTPUT SHAFT
4 - FRONT BAND 14 - SEAL
5 - FRONT CLUTCH 15 - INTERMEDIATE SHAFT
6 - REAR CLUTCH 16 - OVERDRIVE OVERRUNNING CLUTCH
7 - PLANETARIES 17 - DIRECT CLUTCH SPRING
8 - REAR BAND 18 - OVERDRIVE PISTON RETAINER
9 - OVERRUNNING CLUTCH 19 - FILTER
10 - OVERDRIVE CLUTCH 20 - VALVE BODY
Fig. 2 Transmission Part And Serial Number
Location
1 - PART NUMBER
2 - BUILD DATE
3 - SERIAL NUMBER
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 91
AUTOMATIC TRANSMISSION - 46RE (Continued)

FOURTH GEAR POWERFLOW
Fourth gear overdrive range is electronically con-
trolled and hydraulically activated. Various sensor
inputs are supplied to the powertrain control module
to operate the overdrive solenoid on the valve body.
The solenoid contains a check ball that opens and
closes a vent port in the 3-4 shift valve feed passage.
The overdrive solenoid (and check ball) are not ener-
gized in first, second, third, or reverse gear. The vent
port remains open, diverting line pressure from the
2-3 shift valve away from the 3-4 shift valve. The
overdrive control switch must be in the ON position
to transmit overdrive status to the PCM. A 3-4
upshift occurs only when the overdrive solenoid is
energized by the PCM. The PCM energizes the over-
drive solenoid during the 3-4 upshift. This causes the
solenoid check ball to close the vent port allowing
line pressure from the 2-3 shift valve to act directly
on the 3-4 upshift valve. Line pressure on the 3-4
shift valve overcomes valve spring pressure moving
the valve to the upshift position. This action exposes
the feed passages to the 3-4 timing valve, 3-4 quick
fill valve, 3-4 accumulator, and ultimately to the
overdrive piston. Line pressure through the timingvalve moves the overdrive piston into contact with
the overdrive clutch. The direct clutch is disengaged
before the overdrive clutch is engaged. The boost
valve provides increased fluid apply pressure to the
overdrive clutch during 3-4 upshifts, and when accel-
erating in fourth gear. The 3-4 accumulator cushions
overdrive clutch engagement to smooth 3-4 upshifts.
The accumulator is charged at the same time as
apply pressure acts against the overdrive piston.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION
Automatic transmission problems can be a result of
poor engine performance, incorrect fluid level, incor-
rect linkage or cable adjustment, band or hydraulic
control pressure adjustments, hydraulic system mal-
functions or electrical/mechanical component malfunc-
tions. Begin diagnosis by checking the easily
accessible items such as: fluid level and condition,
linkage adjustments and electrical connections. A road
test will determine if further diagnosis is necessary.
Fig. 8 Direct Drive Powerflow
1 - FRONT CLUTCH APPLIED 6 - INPUT SHAFT
2 - OVER-RUNNING CLUTCH FREE-WHEELING 7 - OVER-RUNNING CLUTCH FREE-WHEELING
3 - OUTPUT SHAFT 8 - REAR CLUTCH APPLIED
4 - REAR CLUTCH APPLIED 9 - FRONT CLUTCH APPLIED
5 - OUTPUT SHAFT 10 - INPUT SHAFT
21 - 96 AUTOMATIC TRANSMISSION - 46REBR/BE
AUTOMATIC TRANSMISSION - 46RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NO KICKDOWN OR
NORMAL DOWNSHIFT1. Throttle Linkage Mis-adjusted. 1. Adjust linkage.
2. Accelerator Pedal Travel
Restricted.2. Verify floor mat is not under pedal, repair
worn accelerator cable or bent brackets.
3. Valve Body Hydraulic Pressures
Too High or Too Low Due to Valve
Body Malfunction or Incorrect
Hydraulic Control Pressure
Adjustments.3. Perform hydraulic pressure tests to
determine cause and repair as required.
Correct valve body pressure adjustments as
required.
4. Governor Circuit Electrical Fault. 4. Test with DRBTscan tool and repair as
required.
5. Valve Body Malfunction. 5. Perform hydraulic pressure tests to
determine cause and repair as required.
Correct valve body pressure adjustments as
required.
6. TPS Malfunction. 6. Replace sensor, check with DRBTscan
tool.
7. PCM Malfunction. 7. Check with DRBTscan tool and replace
if required.
8. Valve Body Malfunction. 8. Repair sticking 1-2, 2-3 shift valves,
governor plugs, 3-4 solenoid, 3-4 shift
valve, 3-4 timing valve.
STUCK IN LOW GEAR
(WILL NOT UPSHIFT)1. Throttle Linkage Mis-adjusted/
Stuck.1. Adjust linkage and repair linkage if worn
or damaged. Check for binding cable or
missing return spring.
2. Gearshift Linkage Mis-adjusted. 2. Adjust linkage and repair linkage if worn
or damaged.
3. Governor Component Electrical
Fault.3. Check operating pressures and test with
DRBTscan tool, repair faulty component.
4. Front Band Out of Adjustment. 4. Adjust Band.
5. Clutch or Servo Malfunction. 5. Air pressure check operation of clutches
and bands. Repair faulty component.
CREEPS IN NEUTRAL 1. Gearshift Linkage Mis-adjusted. 1. Adjust linkage.
2. Rear Clutch Dragging/Warped. 2. Disassemble and repair.
3. Valve Body Malfunction. 3. Perform hydraulic pressure test to
determine cause and repair as required.
21 - 106 AUTOMATIC TRANSMISSION - 46REBR/BE
AUTOMATIC TRANSMISSION - 46RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
SLIPS IN LOW GEAR9D9
ONLY, BUT NOT IN
MANUAL 1 POSITIONOverrunning Clutch Faulty. Replace overrunning clutch.
GROWLING, GRATING OR
SCRAPING NOISES1. Drive Plate Broken. 1. Replace.
2. Torque Converter Bolts Hitting
Dust Shield.2. Dust shield bent. Replace or repair.
3. Planetary Gear Set Broken/
Seized.3. Check for debris in oil pan and repair as
required.
4. Overrunning Clutch Worn/Broken. 4. Inspect and check for debris in oil pan.
Repair as required.
5. Oil Pump Components Scored/
Binding.5. Remove, inspect and repair as required.
6. Output Shaft Bearing or Bushing
Damaged.6. Remove, inspect and repair as required.
7. Clutch Operation Faulty. 7. Perform air pressure check and repair as
required.
8. Front and Rear Bands Mis-
adjusted.8. Adjust bands.
DRAGS OR LOCKS UP 1. Fluid Level Low. 1. Check and adjust level.
2. Clutch Dragging/Failed 2. Air pressure check clutch operation and
repair as required.
3. Front or Rear Band Mis-adjusted. 3. Adjust bands.
4. Case Leaks Internally. 4. Check for leakage between passages in
case.
5. Servo Band or Linkage
Malfunction.5. Air pressure check servo operation and
repair as required.
6. Overrunning Clutch Worn. 6. Remove and inspect clutch. Repair as
required.
7. Planetary Gears Broken. 7. Remove, inspect and repair as required
(look for debris in oil pan).
8. Converter Clutch Dragging. 8. Check for plugged cooler. Perform flow
check. Inspect pump for excessive side
clearance. Replace pump as required.
NO 4-3 DOWNSHIFT 1. Circuit Wiring and/or Connectors
Shorted.1. Test wiring and connectors with test lamp
and volt/ohmmeter. Repair wiring as
necessary. Replace connectors and/or
harnesses as required.
2. PCM Malfunction. 2. Check PCM operation with DRBTscan
tool. Replace PCM only if faulty.
3. TPS Malfunction 3. Check TPS with DRBTscan tool at PCM.
4. Lockup Solenoid Not Venting. 4. Remove valve body and replace solenoid
assembly if plugged or shorted.
5. Overdrive Solenoid Not Venting. 5. Remove valve body and replace solenoid
if plugged or shorted.
6. Valve Body Valve Sticking. 6. Repair stuck 3-4 shift valve or lockup
timing valve.
21 - 108 AUTOMATIC TRANSMISSION - 46REBR/BE
AUTOMATIC TRANSMISSION - 46RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NO 4-3 DOWNSHIFT
WHEN CONTROL SWITCH
IS TURNED OFF1. Control Switch Open/Shorted. 1. Test and replace switch if faulty.
2. Overdrive Solenoid Connector
Shorted.2. Test solenoids and replace if seized or
shorted.
3. PCM Malfunction. 3. Test with DRBTscan tool. Replace PCM
if faulty.
4. Valve Body Stuck Valves. 4. Repair stuck 3-4, lockup or lockup timing
valve.
CLUNK NOISE FROM
DRIVELINE ON CLOSED
THROTTLE 4-3
DOWNSHIFT1. Transmission Fluid Low. 1. Add Fluid.
2. Throttle Cable Mis-adjusted. 2. Adjust cable.
3. Overdrive Clutch Select Spacer
Wrong Spacer.3. Replace overdrive piston thrust plate
spacer.
3-4 UPSHIFT OCCURS
IMMEDIATELY AFTER 2-3
SHIFT1. Overdrive Solenoid Connector or
Wiring Shorted.1. Test connector and wiring for loose
connections, shorts or ground and repair as
needed.
2. TPS Malfunction. 2. Test TPS and replace as necessary.
Check with DRBTscan tool.
3. PCM Malfunction. 3. Test PCM with DRBTscan tool and
replace controller if faulty.
4. Overdrive Solenoid Malfunction. 4. Replace solenoid.
5. Valve Body Malfunction. 5. Remove, disassemble, clean and inspect
valve body components. Make sure all
valves and plugs slide freely in bores.
Polish valves with crocus cloth if needed.
WHINE/NOISE RELATED
TO ENGINE SPEED1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Shift Cable Incorrect Routing. 2. Check shift cable for correct routing.
Should not touch engine or bell housing.
BR/BEAUTOMATIC TRANSMISSION - 46RE 21 - 109
AUTOMATIC TRANSMISSION - 46RE (Continued)