2002 DODGE RAM oil pressure

(10) Remove fuel rail (with injectors attached)
from engine.
(11) Remove the clip(s) retaining the injector(s) to
fuel rail (Fig. 27) or (Fig. 28).
REMOVAL - 8.0L
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE EVEN WITH THE ENGINE OFF.
BEFORE SERVICING FUEL RAIL, FUEL SYSTEM
PRESSURE MUST BE RELEASED.
(1) Remove negative battery cable at battery.
(2) Remove air cleaner housing and tube.
(3) Perform fuel pressure release procedure. Refer
to Fuel Delivery System section of this group.
(4) Disconnect throttle body linkage and remove
throttle body from intake manifold. Refer to Throttle
Body removal in this group.
(5) Remove ignition coil pack and bracket assem-
bly (Fig. 29) at intake manifold and right engine
valve cover (four bolts).
(6) Remove upper half of intake manifold. Refer to
Engines for procedures.
(7) Disconnect electrical connectors at all fuel
injectors. To remove connector refer to (Fig. 30). Push
red colored slider away from injector (1). While push-
ing slider, depress tab (2) and remove connector (3)
from injector. The factory fuel injection wiring har-
ness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification.
(8) Disconnect fuel line quick-connect fitting at
left-rear end of fuel rail. A special 3/8 inch fuel line
disconnection tool will be necessary.
Fig. 26 Remove/Install Fuel Injector Connector
Fig. 27 Fuel Injector MountingÐTypical
1 - CLIP
2 - INJECTOR
3 - FUEL RAIL
Fig. 28 Injector Retaining ClipsÐTypical Injector
1 - PLIERS
2 - INJECTOR CLIP
3 - FUEL INJECTOR
4 - FUEL RAIL
14 - 16 FUEL DELIVERY - GASOLINEBR/BE
FUEL RAIL (Continued)

(9) Remove the six fuel rail mounting bolts from
the lower half of intake manifold (Fig. 31).
(10) Gently rock and pull theleftfuel rail until
the fuel injectors just start to clear the intake mani-
fold. Gently rock and pull therightfuel rail until
the fuel injectors just start to clear the intake mani-
fold. Repeat this procedure (left/right) until all fuel
injectors have cleared the intake manifold.
(11) Remove fuel rail (with injectors attached)
from engine.
(12) Remove the clip(s) retaining the injector(s) to
fuel rail (Fig. 27) or (Fig. 28).
INSTALLATION
INSTALLATION - 5.9L
(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) Position the fuel rail/fuel injector assembly to
the injector openings on the intake manifold.
(4) Guide each injector into the intake manifold.
Be careful not to tear the injector o-ring.
Fig. 29 Ignition Coil Pack and Mounting BracketÐ
8.0L V-10 Engine
1 - COIL PACKS AND BRACKET
2 - MOUNTING BOLTS (4)
Fig. 30 Remove/Install Fuel Injector Connector
Fig. 31 Fuel Rail Mounting BoltsÐ8.0L V-10
EngineÐTypical
1 - FUEL RAIL
2 - ELECTRICAL CONNECTOR
3 - MOUNTING BOLTS (6)
4 - INTAKE MANIFOLD LOWER HALF
5 - FUEL PRESSURE TEST PORT
6 - FUEL INJECTORS (10)
BR/BEFUEL DELIVERY - GASOLINE 14 - 17
FUEL RAIL (Continued)

(5) Push therightfuel rail down until fuel injec-
tors have bottomed on injector shoulder. Push the
leftfuel rail down until fuel injectors have bottomed
on injector shoulder.
(6) Install fuel rail mounting bolts.
(7) Connect electrical connector to intake manifold
air temperature sensor.
(8) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 26). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector.
(9) Install the A/C support bracket (if equipped).
(10) Install throttle body to intake manifold. Refer
to Throttle Body installation in this section of the
group.
(11) Install fuel tube (line) at side of fuel rail.
Refer to Quick-Connect Fittings for procedures.
(12) Install air cleaner.
(13) Connect battery cable to battery.
(14) Start engine and check for leaks.
INSTALLATION - 8.0L
(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.
NOTE: The fuel injector electrical connectors on all
10 injectors should be facing to the right (passen-
ger) side of the vehicle (Fig. 31).
(3) Position the fuel rail/fuel injector assembly to
the injector openings on the intake manifold.
(4) Guide each injector into the intake manifold.
Be careful not to tear the injector o-ring.
(5) Push therightfuel rail down until fuel injec-
tors have bottomed on injector shoulder. Push the
leftfuel rail down until fuel injectors have bottomed
on injector shoulder.
(6) Install the six fuel rail mounting bolts into the
lower half of intake manifold. Tighten bolts to 15
N´m (136 in. lbs.) torque.
(7) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 30). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector. The injector wir-
ing harness is numerically tagged.
(8) Install upper half of intake manifold. Refer to
Engines for procedures.
(9) Connect main fuel line at fuel rail. Refer to
Quick-Connect Fittings for procedures.
(10) Install ignition coil pack and bracket assem-
bly at intake manifold and right engine valve cover
(four bolts).(11) Install throttle body to intake manifold. Refer
to Throttle Body removal in this group.
(12) Install throttle body linkage to throttle body.
(13) Install air cleaner tube and housing.
(14) Install negative battery cable at battery.
(15) Start engine and check for leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.
A fuel tank check valve(s) is mounted into the top
of the fuel tank (or pump module). Refer to Emission
Control System for fuel tank check valve information.
An evaporation control system is connected to the
rollover valve(s) to reduce emissions of fuel vapors
into the atmosphere. When fuel evaporates from the
fuel tank, vapors pass through vent hoses or tubes to
a charcoal canister where they are temporarily held.
When the engine is running, the vapors are drawn
into the intake manifold. Certain models are also
equipped with a self-diagnosing system using a Leak
Detection Pump (LDP). Refer to Emission Control
System for additional information.
REMOVAL
WARNING: GASOLINE POWERED ENGINES: THE
FUEL SYSTEM IS UNDER A CONSTANT PRESSURE
EVEN WITH THE ENGINE OFF. BEFORE SERVICING
THE FUEL TANK, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO THE FUEL SYSTEM
PRESSURE RELEASE PROCEDURE BEFORE SER-
VICING THE FUEL TANK.
Two different procedures may be used to drain fuel
tank (lowering tank or using DRB scan tool). When
equipped with a diesel engine, the DRB scan tool
cannot be used (no electric fuel pump).
The quickest draining procedure involves lowering
the fuel tank.
Gasoline Powered Engines:As an alternative
procedure, the electric fuel pump may be activated
allowing tank to be drained at fuel rail connection.
Refer to DRB scan tool for fuel pump activation pro-
cedures. Before disconnecting fuel line at fuel rail,
release fuel pressure. Refer to the Fuel System Pres-
sure Release Procedure in this group for procedures.
14 - 18 FUEL DELIVERY - GASOLINEBR/BE
FUEL RAIL (Continued)

(2) Clean the area around the sensor before
removal.
(3) Remove the two sensor mounting bolts.
(4) Remove the sensor from the intake manifold.
INSTALLATION
INSTALLATION - 5.9L
The MAP sensor is located on the front of the
throttle body (Fig. 35). An L-shaped rubber fitting is
used to connect the MAP sensor to throttle body (Fig.
36).
(1) Install rubber L-shaped fitting to MAP sensor.
(2) Position sensor to throttle body while guiding
rubber fitting over throttle body vacuum nipple.
(3) Install MAP sensor mounting bolts (screws).
Tighten screws to 3 N´m (25 in. lbs.) torque.
(4) Install air cleaner.
INSTALLATION - 8.0L
The MAP sensor is mounted into the right upper
side of the intake manifold (Fig. 37). A rubber gasket
is used to seal the sensor to the intake manifold. The
rubber gasket is part of the sensor and is not ser-
viced separately.
(1) Check the condition of the sensor seal. Clean
the sensor and lubricate the rubber gasket with clean
engine oil.
(2) Clean the sensor opening in the intake mani-
fold.
(3) Install the sensor into the intake manifold.
(4) Install sensor mounting bolts. Tighten bolts to
2 N´m (20 in. lbs.) torque.
(5) Install the electrical connector to sensor.
O2 SENSOR
DESCRIPTION
The Oxygen Sensors (O2S) are attached to, and
protrude into the vehicle exhaust system. Depending
on the emission package, the vehicle may use a total
of either 2 or 4 sensors.
Medium and Heavy Duty 8.0L V-10 Engine:
Four sensors are used (2 upstream, 1 pre-catalyst
and 1 post-catalyst). With this emission package, the
1/1 upstream sensor (left side) is located in the left
exhaust downpipe before both the pre-catalyst sensor
(1/2), and the main catalytic convertor. The 2/1
upstream sensor (right side) is located in the right
exhaust downpipe before both the pre-catalyst sensor
(1/2), and the main catalytic convertor. The pre-cata-
lyst sensor (1/2) is located after the 1/1 and 2/1 sen-
sors, and just before the main catalytic convertor.
The post-catalyst sensor (1/3) is located just after the
main catalytic convertor.
Heavy Duty 5.9L Engine:Two sensors are used.
They arebothreferred to as upstream sensors (left
side is referred to as 1/1 and right side is referred to
as 2/1). With this emission package, a sensor is
located in each of the exhaust downpipes before the
main catalytic convertor.
OPERATION
An O2 sensor is a galvanic battery that provides
the PCM with a voltage signal (0-1 volt) inversely
proportional to the amount of oxygen in the exhaust.
In other words, if the oxygen content is low, the volt-
age output is high; if the oxygen content is high the
output voltage is low. The PCM uses this information
to adjust injector pulse-width to achieve the
14.7±to±1 air/fuel ratio necessary for proper engine
operation and to control emissions.
The O2 sensor must have a source of oxygen from
outside of the exhaust stream for comparison. Cur-
rent O2 sensors receive their fresh oxygen (outside
air) supply through the O2 sensor case housing.
Four wires (circuits) are used on each O2 sensor: a
12±volt feed circuit for the sensor heating element; a
ground circuit for the heater element; a low-noise
sensor return circuit to the PCM, and an input cir-
cuit from the sensor back to the PCM to detect sen-
sor operation.
Oxygen Sensor Heaters/Heater Relays:
Depending on the emissions package, the heating ele-
ments within the sensors will be supplied voltage
from either the ASD relay, or 2 separate oxygen sen-
sor relays. Refer to 8, Wiring Diagrams to determine
which relays are used.
The O2 sensor uses a Positive Thermal Co-efficient
(PTC) heater element. As temperature increases,
resistance increases. At ambient temperatures
Fig. 37 MAP Sensor LocationÐ8.0L V-10 EngineÐ
Typical
1 - MAP SENSOR
2 - MOUNTING BOLTS
3 - THROTTLE BODY
BR/BEFUEL INJECTION - GASOLINE 14 - 45
MANIFOLD ABSOLUTE PRESSURE SENSOR (Continued)

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)

STANDARD PROCEDURE
STANDARD PROCEDURES - WATER DRAINING
AT FUEL FILTER
Refer to Fuel Filter/Water Separator removal/in-
stallation for procedures.
STANDARD PROCEDURES - CLEANING FUEL
SYSTEM PARTS
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and pos-
sible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
STANDARD PROCEDURE - AIR BLEED
A certain amount of air becomes trapped in the
fuel system when fuel system components on the
supply and/or high-pressure side are serviced or
replaced. Primary air bleeding is accomplished using
the electric fuel transfer (lift) pump. If the vehicle
has been allowed to run completely out of fuel, the
fuel injectors must also be bled as the fuel injection
pumpis notself-bleeding (priming).
Servicing or replacing components on the fuel
return side will not require air bleeding.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE.
(1) Loosen, but do not remove, banjo bolt (test port
fitting) holding low-pressure fuel supply line to side
of fuel injection pump (Fig. 11). Place a shop towel
around banjo fitting to catch excess fuel.
The fuel transfer (lift) pump is self-priming: When
the key is first turned on (without cranking engine),
the pump operates for approximately 2 seconds and
then shuts off. The pump will also operate for up to
25 seconds after the starter is quickly engaged, and
then disengaged without allowing the engine to start.
The pump shuts off immediately if the key is on and
the engine stops running.
(2) Turn key to CRANK position and quickly
release key to ON position before engine starts. Thiswill operate fuel transfer pump for approximately 25
seconds.
(3) If fuel is not present at fuel supply line after
25 seconds, turn key OFF. Repeat previous step until
fuel is exiting at fuel supply line.
(4) Tighten banjo bolt at fuel supply line to 24 N´m
(18 ft. lbs.) torque. Primary air bleeding is now com-
pleted.
(5) Attempt to start engine. If engine will not
start, proceed to following steps.If engine does
start, it may run erratically and be very noisy
for a few minutes. This is a normal condition.
(6)Continue to next step if:
²The vehicle fuel tank has been allowed to run
empty
²The fuel injection pump has been replaced
²High-pressure fuel lines have been replaced
²Vehicle has not been operated after an extended
period
CAUTION: Do not engage the starter motor for more
than 30 seconds at a time. Allow two minutes
between cranking intervals.
(7) Perform previous air bleeding procedure steps
using fuel transfer pump. Be sure fuel is present at
fuel supply line (Fig. 11) before proceeding.
Fig. 11 Fuel Supply Line Banjo Bolt
1 - FUEL SUPPLY LINE
2 - FUEL RETURN LINE
3 - BANJO BOLT (TEST PORT FITTING)
4 - OVERFLOW VALVE
5 - BANJO FITTING
BR/BEFUEL DELIVERY - DIESEL 14 - 61
FUEL DELIVERY - DIESEL (Continued)

(1) Remove hose clamp and crankcase vent hose at
crankcase breather (Fig. 26). Remove crankcase
breather from gear cover. Breather threads into
cover.
(2) Remove injection pump nut and washer (Fig.
27). Locate keyway behind washer.
(3) Be sure keyway aligning fuel injection pump
shaft to injection pump gear is in proper position and
pump gear has not slipped on pump shaft.
The following steps will require removing timing
gear cover to gain access to timing gears. Refer to
Group 9, Engines for procedures.
(4) Use a T-type puller to separate injection pump
gear from pump shaft.
(5) Be sure keyway has been installed with arrow
pointed torearof pump (Fig. 28).
(6)Pump timing has been calibrated to pump
keyway. Be sure 3±digit number on pump key-
way (Fig. 28) matches 3±digit number on fuel
injection pump data plate. Plate is located on
side of injection pump (Fig. 29). Twenty±one dif-
ferent calibrated keyways/pumps are available.
(7) Verify timing marks on crank, cam and pump
are aligned (Fig. 30).
(8) Perform necessary gear alignment/repairs as
needed.
(9) Install crankcase breather to gear cover. Install
hose clamp and crankcase vent hose to breather (Fig.
26).
(10) After repairs are completed, erase DTC using
DRB Scan Tool.
REMOVAL
CAUTION: Refer to Cleaning Fuel System Parts.
(1) Disconnect both negative battery cables at both
batteries. Cover and isolate ends of cables.
(2) Thoroughly clean fuel lines at cylinder head
and injection pump ends. Thoroughly clean fuel injec-
tion pump and supply/return lines at side of pump.
(3) Disconnect 9±way electrical connector at Fuel
Pump Control Module (FPCM) (Fig. 31).
(4) Remove fuel return line at side of injection
pump by removing overflow valve (Fig. 32). Place rag
beneath overflow valve to catch excess fuel.
(5) Remove fuel supply line at side of injection
pump by removing banjo bolt (Fig. 32). Also remove
same line at top of fuel filter housing (banjo bolt).
(6) Remove all high-pressure fuel lines, intake air
tube, accelerator pedal position sensor, air intake
housing, engine oil dipstick tube, wiring clips, electri-
cal cables at intake heaters and engine lifting
bracket. Refer to High-Pressure Fuel Line Removal/
Installation. All of these items are covered in this
procedure.
(7) Remove hose clamp at crankcase vent hose
(Fig. 33) and remove hose from canister.
(8) Remove (unscrew) canister (Fig. 33) from gear
cover.
Fig. 30 Checking Fuel Injection Pump Gear Timing
1 - PUMP SHAFT
2 - KEYWAY
3 - PUMP GEAR
4 - CAM GEAR
5 - CRANKSHAFT GEAR
Fig. 31 FPCM 9±Way Connector
1 - FPCM ELECTRICAL CONNECTOR
2 - HIGH-PRESSURE FUEL LINES
3 - FITTINGS
4 - FUEL INJECTION PUMP
5 - FPCM
14 - 72 FUEL DELIVERY - DIESELBR/BE
FUEL INJECTION PUMP (Continued)

The machined tapers on both injection pump
shaft and injection pump gear (Fig. 42) must be
absolutely dry, clean and free of any dirt or oil
film. This will ensure proper gear-to-shaft tight-
ening.
(5) Clean pump gear and pump shaft at machined
tapers (Fig. 42) with an evaporative type cleaner
such as brake cleaner.
Keyway Installation:
(6) The pump/gear keyway has an arrow and a
3±digit number stamped at top edge (Fig. 41). Posi-
tion keyway into pump shaft witharrow pointed to
rear of pump.Also be sure 3±digit number stamped
to top of keyway is same as 3±digit number stamped
to injection pump data plate (Fig. 43). If wrong key-
way is installed, a diagnostic trouble code may be
set.
(7) Position pump assembly to mounting flange on
gear cover while aligning injection pump shaft
through back of injection pump gear. When installing
pump, dowel (Fig. 42) on mounting flange must align
to hole in front of pump.(8) After pump is positioned flat to mounting
flange, install four pump mounting nuts and tighten
finger tight only. Do not attempt a final tightening at
this time.Do not attempt to tighten (pull) pump
to gear cover using mounting nuts. Damage to
pump or gear cover may occur. The pump must
be positioned flat to its mounting flange before
attempting to tighten mounting nuts.
(9) To prevent damage or cracking of components,
tighten nuts/bolts in the following sequence:
(a) Install injection pump shaft washer and nut
to pump shaft. Tighten nutfinger tight only.
(b) Install 2 rear/lower pump mounting bolts
finger tight only.
(c) Do preliminary tightening of injection pump
shaft nut to 30 N´m (15±22 ft. lbs.) torque.This is
not the final torque.
(d) Tighten 4 pump mounting nuts to 43 N´m
(32 ft. lbs.) torque.
(e) Tighten 2 rear/lower pump bracket-to-pump
bolts 24 N´m (18 ft. lbs.) torque.
(f) Do final tightening of injection pump shaft
nut to 170 N´m (125 ft. lbs.) torque. Use barring
tool to prevent engine from rotating when tighten-
ing gear.
(10) Install canister (Fig. 33) to gear cover.
(11) Install crankcase vent hose (Fig. 33) to canis-
ter and install hose clamp.
(12) Using new gaskets, install fuel return line
and overflow valve to side of injection pump (Fig. 32).
Tighten overflow valve to 24 N´m (18 ft. lbs.) torque.
(13) Using new gaskets, install fuel supply line to
side of injection pump and top of fuel filter housing
(Fig. 32). Tighten banjo bolts to 24 N´m (18 ft. lbs.)
torque.
(14) Install all high-pressure fuel lines, intake air
tube, accelerator pedal position sensor, air intake
housing, engine oil dipstick tube, wiring clips, electri-
cal cables at intake heaters and engine lifting
bracket. Refer to High-Pressure Fuel Line Removal/
Installation. All of these items are covered in this
procedure.
(15) Connect 9±way electrical connector to Fuel
Pump Control Module (FPCM) (Fig. 31).
(16) Connect both negative battery cables to both
batteries.
(17) Bleed air from fuel system.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE).
(18) Check system for fuel or engine oil leaks.
Fig. 43 Injection Pump Data Plate Location
1 - PUMP DATA PLATE
14 - 76 FUEL DELIVERY - DIESELBR/BE
FUEL INJECTION PUMP (Continued)