2002 DODGE RAM relay

(7) Attach the other jumper wire (12V +) to termi-
nal number 86. This will activate the relay. Continu-
ity should now be present between terminals number
87 and 30. Continuity should not be present between
terminals number 87A and 30.
(8) Disconnect jumper wires from relay and 12 Volt
power source.
(9) If continuity or resistance tests did not pass,
replace relay. If tests passed, refer to 8, Wiring Dia-
grams for (fuel system) relay wiring schematics and
for additional circuit information.
REMOVAL
The fuel heater relay is located in the Power Dis-
tribution Center (PDC) (Fig. 22). Refer to label under
PDC cover for relay location.
(1) Remove PDC cover.
(2) Remove relay from PDC.
(3) Check condition of relay terminals and PDC
connector terminals for damage or corrosion. Repair
if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
INSTALLATION
The fuel heater relay is located in the Power Dis-
tribution Center (PDC) (Fig. 22). Refer to label under
PDC cover for relay location.
(1) Install relay to PDC.
(2) Install cover to PDC.
FUEL INJECTION PUMP
DESCRIPTION
DESCRIPTIONÐFUEL PUMP 245 H.P.
Although the fuel injection pump on the 245 horse-
power engine appears similar to other VP 44 injec-
tion pumps, there are internal differences that make
it unique. If pump replacement is necessary, be sure
to verify pump number. The pump number can be
found on the Fuel Injection Pump Data Plate (Fig.
23).
DESCRIPTIONÐFUEL PUMP 235 H.P.
The fuel injection pump is mounted to the rear of
the timing gear housing on the left side of engine
(Fig. 24).
Fig. 22 Power Distribution Center (PDC) Location
1 - CLIP
2 - BATTERY
3 - TRAY
4 - NEGATIVE CABLE
5 - POSITIVE CABLE
6 - CLIP
7 - FENDER INNER SHIELD
8 - POWER DISTRIBUTION CENTER
Fig. 23 Fuel Injection Pump Data Plate Location
1 - PUMP DATA PLATE
BR/BEFUEL DELIVERY - DIESEL 14 - 69
FUEL HEATER RELAY (Continued)

Refer to Fuel Transfer Pump Description/Operation
for an operational description of transfer pump.
The fuel transfer (lift) pump is located on left side
of engine and above starter motor (Fig. 61).
An improperly operating fuel transfer pump, a
plugged or dirty fuel filter, or a defective overflow
valve can cause low engine power, excessive white
smoke and/or hard engine starting.
Before performing following tests, inspect fuel sup-
ply and return lines for restrictions, kinks or leaks.
Fuel leaking from pump casing indicates a leaking
pump which must be replaced.
Pressure Test:Because the transfer pump is oper-
ating at two different pressure cycles (engine running
and engine cranking), two different pressure tests
will be performed.
(1) Remove protective cap at test port (Fig. 62).
Clean area around cap/fitting before cap removal.
(2) Install Special Fuel Pressure Test Gauge 6828
(or equivalent) to fitting at test port (Fig. 62).
(3) To prevent engine from starting, remove fuel
system relay (fuel injection pump relay). Relay is
located in Power Distribution Center (PDC). Refer to
label under PDC cover for relay location.(4) Using key, crank engine over while observing
gauge. Pressure should be 5±7 psi.
(5) Re-install fuel system relay to PDC.
(6) Start engine and record fuel pressure. Pressure
should be aminimumof 69 kPa (10 psi) at idle
speed.
Fig. 61 Fuel Transfer Pump Location
1 - OIL PRESSURE SENSOR
2 - PUMP BRACKET NUTS (3)
3 - SUPPORT BRACKET BOLT
4 - BANJO BOLT (REAR)
5 - FUEL SUPPLY LINE
6 - ELECTRICAL CONNECTOR
7 - BANJO BOLT (FRONT)
8 - FUEL TRANSFER PUMP
Fig. 62 Fuel Pressure Test Port Fitting
1 - FUEL PRESSURE TEST PORT
Fig. 63 Fuel Return and Supply Line Quick-Connect
Locations
1 - FUEL RETURN LINE
2 - QUICK-CONNECT FITTINGS
3 - FUEL SUPPLY LINE
BR/BEFUEL DELIVERY - DIESEL 14 - 85
FUEL TRANSFER PUMP (Continued)

(7) Because fuel pump relay was removed, a Diag-
nostic Trouble Code (DTC) may have been set. After
testing is completed, and relay has been installed,
use DRB scan tool to remove DTC.
Fuel Supply Restriction Test:
Due to very small vacuum specifications, the DRB
scan tool along with the Periphal Expansion Port
(PEP) Module and 0±15 psi transducer must be used.
(8) Verify transfer pump pressure is OK before
performing restriction test.
(9) Locate and disconnect fuel supply line quick-
connect fitting at left-rear of engine (Fig. 63). After
disconnecting line, plastic clip will remain attached
to metal fuel line at engine. Carefully remove clip
from metal line. Snap same clip into fuel supply
hose.
(10) Install Special Rubber Adapter Hose Tool
6631 (3/8º) into ends of disconnected fuel supply line.
(11) Install transducer from PEP module to brass
ªTº fitting on tool 6631.
(12) Hook up DRB scan tool to transducer.
WARNING: DO NOT STAND IN LINE WITH THE
COOLING FAN FOR THE FOLLOWING STEPS.
(13) Start engine and record vacuum reading with
engine speed at high-idle (high-idle means engine
speed is at 100 percent throttle and no load). The
fuel restriction testMUSTbe done with engine speed
at high-idle.
(14) If vacuum reading islessthan 6 in/hg. (0±152
mm hg.), test is OK. If vacuum reading ishigher
than 6 in/hg. (152 mm hg.), restriction exists in fuel
supply line or in fuel tank module. Check fuel supply
line for damage, dents or kinking. If OK, remove
module and check module and lines for blockage.
Also check fuel pump inlet filter at bottom of module
for obstructions.
Testing For Air Leaks in Fuel Supply Side:
(15) A 3±foot section of 3/8º I.D. clear tubing is
required for this test.
(16) Using a tire core valve removal tool, carefully
remove core valve from inlet fitting test port.
(17) Attach and clamp the 3/8ºclear hose to fitting
nipple.
(18) Place other end of hose into a large clear con-
tainer. Allow hose to loop as high as possibleabove
test port.
(19) The fuel transfer pump can be put into a 25
second run (test) mode if key is quickly turned to
crank position and released back to run position
without starting engine.
To prevent engine from starting in this test, first
remove fuel system relay (fuel injection pump relay).
Relay is located in Power Distribution Center (PDC).
Refer to label under PDC cover for relay location.
Because fuel pump relay was removed, a DiagnosticTrouble Code (DTC) may have been set. After testing
is completed, and relay has been installed, use DRB
scan tool to remove DTC.
(20) Allow air to purge from empty hose before
examining for air bubbles. Air bubbles should not be
present.
(21) If bubbles are present, check for leaks in sup-
ply line to fuel tank.
(22) If supply line is not leaking, remove fuel tank
module and remove filter at bottom of module (filter
snaps to module). Check for leaks between supply
nipple at top of module, and filter opening at bottom
of module. Replace module if necessary.
(23) After performing test, install core back into
test fitting. Before installing protective cap, be sure
fitting is not leaking.
REMOVAL
The fuel transfer pump (fuel lift pump) is located
on left side of engine, below and rearward of fuel fil-
ter (Fig. 64).
(1) Disconnect both negative battery cables at both
batteries.
Fig. 64 Fuel Transfer Pump Location
1 - OIL PRESSURE SENSOR
2 - PUMP BRACKET NUTS (3)
3 - SUPPORT BRACKET BOLT
4 - BANJO BOLT (REAR)
5 - FUEL SUPPLY LINE
6 - ELECTRICAL CONNECTOR
7 - BANJO BOLT (FRONT)
8 - FUEL TRANSFER PUMP
14 - 86 FUEL DELIVERY - DIESELBR/BE
FUEL TRANSFER PUMP (Continued)

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)

(g) If any of these conditions occur, replace injec-
tor.
(2) Thoroughly clean fuel injector cylinder head
bore with special Cummins wire brush tool or equiv-
alent (Fig. 24). Blow out bore hole with compressed
air.
(3) The bottom of fuel injector is sealed to cylinder
head bore with a copper sealing washer (shim) of a
certain thickness. A new shim with correct thickness
must always be re-installed after removing injector.
Measure thickness of injector shim (Fig. 23).Shim
Thickness: 1.5 mm (.060º)
(4) Install new shim (washer) to bottom of injector
(Fig. 22). Apply light coating of clean engine oil to
washer. This will keep washer in place during instal-
lation.
(5) Install new o-ring to fuel injector. Apply small
amount of clean engine oil to o-ring.
(6) Note fuel inlet hole on side of fuel injector. This
hole must be positioned towards injector connector
tube. Position injector into cylinder head bore being
extremely careful not to allow injector tip to touch
sides of bore. Press fuel injector into cylinder head
with finger pressure only.Do not use any tools to
press fuel injector into position. Damage to
machined surfaces may result.
(7) Position fuel injector hold down clamp into
shouldered bolt while aligning slot in top of injector
into groove in bottom of clamp. Tighten opposite
clamp bolt (Fig. 18) to 10 N´m (89 in. lbs.) torque.
(8) Install new o-ring to fuel injector connector
tube. Apply small amount of clean engine oil to
o-ring.(9) Press injector connector tube into cylinder head
with finger pressure only.Do not use any tools to
press tube into position. Damage to machined
surfaces may result.
(10) Connect high-pressure fuel lines. Refer to
High-Pressure Fuel Lines Removal/Installation.The
fuel line fitting torque is very critical.If fitting
is under torqued, the mating surfaces will not seal
and a high-pressure fuel leak will result. If fitting is
over torqued, the connector and injector will deform
and also cause a high-pressure fuel leak. This leak
will be inside cylinder head and will not be visible
resulting in a possible fuel injector miss and low
power.
(11) Install valve cover. (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION).
(12) (If necessary) install intake manifold air
heater assembly. Refer to Intake Manifold Air Heater
Removal/Installation.
(13) (If necessary) install engine lifting bracket.
Tighten 2 bolts to 77 N´m (57 ft. lbs.) torque.
(14) Connect negative battery cables to both bat-
teries.
(15) Bleed air from high-pressure lines (Refer to 14
- FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE).
FUEL INJECTION PUMP
RELAY
DESCRIPTION
The fuel injection pump relay is located in the
Power Distribution Center (PDC). Refer to label
under PDC cover for relay location.
OPERATION
The Engine Control Module (ECM) energizes the
electric fuel injection pump through the fuel injection
pump relay. Battery voltage is applied to the fuel
injection pump relay at all times. When the key is
turned ON, the relay is energized when a 12±volt sig-
nal is provided by the ECM. When energized,
12±volts is supplied to the Fuel Pump Control Mod-
ule. The Fuel Pump Control Module is located on the
top of the fuel injection pump and is non-servicable.
Fig. 24 Cleaning Cylinder Head Injector BoreÐ
TYPICAL BORE
1 - INJECTOR BORE
2 - WIRE BRUSH
BR/BEFUEL INJECTION - DIESEL 14 - 103
FUEL INJECTOR (Continued)

FUEL TEMPERATURE SENSOR
DESCRIPTION
Two different fuel temperature sensors are used.
One of the sensors is located inside of the Bosch
VP44 fuel injection pump and is a non-serviceable
part. The other fuel temperature sensor is located in
the top of the fuel filter housing and is serviceable
(serviceable if replacing the fuel heater).
OPERATION
The sensor located in the Bosch VP44 fuel injection
pump is used to check fuel temperature within the
injection pump and to set a Diagnostic Trouble Code
(DTC) if a specific high fuel temperature has been
reached. If high temperature has been reached,
engine power will be de-rated by the Engine Control
Module (ECM).
The sensor located in the top of the fuel filter hous-
ing is used to control the fuel heater element. Refer
to Fuel Heater Description and Operation for addi-
tional information.
INTAKE AIR HEATER
DESCRIPTION
The intake manifold air heater element assembly
is located in the top of the intake manifold (Fig. 25).
OPERATION
The air heater elements are used to heat incoming
air to the intake manifold. This is done to help
engine starting and improve driveability with cool or
cold outside temperatures.
Electrical supply for the 2 air heater elements is
controlled by the Engine Control Module (ECM)
through the 2 air heater relays. Refer to Intake Man-
ifold Air Heater Relays for more information.
Two heavy-duty cables connect the 2 air heater ele-
ments to the 2 air heater relays. Each of these cables
will supply approximately 95 amps at 12 volts to an
individual heating element within the heater block
assembly.
Refer to the Powertrain Diagnostic Procedures
manual for an electrical operation and complete
description of the intake heaters, including pre-heat
and post-heat cycles.
REMOVAL
The 2 intake manifold air heater elements are
attached to a metal block located at the top of the
intake manifold (Fig. 26). If servicing either of the
heater elements, the entire block/element assembly
must be replaced.
(1) Disconnect both negative battery cables at both
batteries.
(2) Disconnect clamp from rubber hose at air
intake housing.
(3) Disconnect rubber hose at air intake housing.
Fig. 25 Air Heater Elements Location
1 - AIR HEATER ELEMENTS
2 - LOWER GASKET
3 - BLOCK
4 - UPPER GASKET
Fig. 26 Intake Manifold Air Heater Element Location
1 - AIR HEATER ELEMENTS
2 - LOWER GASKET
3 - BLOCK
4 - UPPER GASKET
14 - 104 FUEL INJECTION - DIESELBR/BE

(4) Remove engine oil dipstick tube mounting bolt
(Fig. 28). Position dipstick tube to the side.(5) Disconnect heater electrical cables at cable
mounting studs (Fig. 28).
(6) Disconnect ground cable bolt and ground cable
from housing (Fig. 27).
(7) Remove 4 housing bolts (Fig. 28).
(8) Remove air intake housing from top of heater
elements.
(9) Remove heater element assembly from intake
manifold.
(10) Clean old gasket material from air intake
housing and intake manifold.
(11) Clean old gasket material from both ends of
heater block (Fig. 26).
INSTALLATION
The 2 intake manifold air heater elements are
attached to a metal block located at the top of the
intake manifold (Fig. 26). If servicing either of the
heater elements, the entire block/element assembly
must be replaced.
(1) Using 2 new gaskets, position element assem-
bly and air housing to intake manifold.
(2) Position ground cable (Fig. 27) to air housing.
(3) Install 4 housing bolts and tighten to 24 N´m
(18 ft. lbs.) torque.
(4) Connect heater cables at cable mounting studs
(Fig. 28).Do not allow the cable eyelets to con-
tact any other metal source other than the
cable nuts/studs.
(5) Install engine oil dipstick tube and mounting
bolt.
(6) Connect rubber hose to air intake housing.
(7) Connect clamp to rubber hose at air intake
housing.
(8) Connect both negative battery cables at both
batteries.
INTAKE AIR HEATER RELAY
DESCRIPTION
The 2 intake manifold air heater relays are located
in the engine compartment, attached to the left inner
fender below the left battery (Fig. 29).
OPERATION
The Engine Control Module (ECM) operates the 2
heating elements through the 2 intake manifold air
heater relays.
Refer to Powertrain Diagnostic Procedures for an
electrical operation and complete description of the
intake heaters, including pre-heat and post-heat
cycles.
Fig. 27 Air Intake Housing (Front View)
1 - GROUND CABLE BOLT
2 - INTAKE AIR HOUSING
3 - CABLE BRACKET HOUSING BOLTS (3)
4 - GROUND CABLE
Fig. 28 Air Intake Housing (Rear View)
1 - TUBE MOUNTING BOLT
2 - HOUSING BOLTS (2)
3 - INTAKE HEATER CABLE MOUNTING STUDS (2)
4 - DIPSTICK TUBE
BR/BEFUEL INJECTION - DIESEL 14 - 105
INTAKE AIR HEATER (Continued)