2002 DODGE RAM ac compressor

8W-42 AIR CONDITIONING-HEATER
Component Page
A/C Compressor Clutch................ 8W-42-5
A/C Compressor Clutch Relay........... 8W-42-5
A/C Heater Temperature Select......... 8W-42-2
A/C High Pressure Switch............. 8W-42-3
A/C Low Pressure Switch.............. 8W-42-3
A/C-Heater Control................. 8W-42-3, 4
Blend Door Actuator.................. 8W-42-2
Blower Motor..................... 8W-42-3, 4
Blower Motor Relay.............. 8W-42-2, 3, 4
Blower Motor Resistor Block............ 8W-42-4
Fuse 2 (JB)......................... 8W-42-2
Fuse 5 (JB)......................... 8W-42-4
Fuse 11 (JB)........................ 8W-42-5
Fuse 12 (PDC)...................... 8W-42-3Component Page
Fuse J (PDC)....................... 8W-42-5
G102............................ 8W-42-2, 3
G105.............................. 8W-42-5
G107.............................. 8W-42-5
G200.............................. 8W-42-2
G201.............................. 8W-42-4
Headlamp Switch.................... 8W-42-4
Joint Connector No. 1............... 8W-42-2, 3
Joint Connector No. 5................. 8W-42-4
Joint Connector No. 8................. 8W-42-2
Junction Block.................. 8W-42-2, 4, 5
Power Distribution Center........... 8W-42-3, 5
Powertrain Control Module........... 8W-42-3, 5
BR/BE8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1

8W-80 CONNECTOR PIN-OUTS
Component Page
4WD Switch........................ 8W-80-4
A/C Compressor Clutch................ 8W-80-4
A/C Heater Control................... 8W-80-4
A/C Heater Temperature Select......... 8W-80-4
A/C High Pressure Switch............. 8W-80-4
A/C Low Pressure Switch.............. 8W-80-5
Accelerator Pedal Position Sensor
(Diesel).......................... 8W-80-5
Aftermarket Trailer Tow Connector...... 8W-80-5
Airbag Control Module................ 8W-80-5
Ambient Temperature Sensor........... 8W-80-6
Ash Receiver Lamp................... 8W-80-6
Automatic Day/Night Mirror............ 8W-80-6
Back-Up Lamp Switch (M/T)........... 8W-80-6
Battery Temperature Sensor............ 8W-80-7
Blend Door Actuator.................. 8W-80-7
Blower Motor....................... 8W-80-7
Blower Motor Resistor Block............ 8W-80-7
Brake Lamp Switch.................. 8W-80-7
Brake Pressure Switch................ 8W-80-8
Bypass Jumper (A/T)................. 8W-80-8
C105.............................. 8W-80-8
C105.............................. 8W-80-8
C106.............................. 8W-80-8
C106.............................. 8W-80-8
C114 .............................. 8W-80-9
C114 .............................. 8W-80-9
C125 (Diesel)....................... 8W-80-9
C125 (Diesel)....................... 8W-80-9
C126 (Diesel)....................... 8W-80-10
C126 (Diesel)....................... 8W-80-10
C129............................. 8W-80-10
C129............................. 8W-80-11
C130 (Diesel)....................... 8W-80-11
C130 (Diesel) (In PDC)............... 8W-80-12
C130 (Gas)........................ 8W-80-13
C130 (Gas) (In PDC)................. 8W-80-14
C134............................. 8W-80-15
C134............................. 8W-80-17
C203............................. 8W-80-18
C203............................. 8W-80-19
C205............................. 8W-80-20
C205............................. 8W-80-20
C206 (Heated Seats)................. 8W-80-20
C206 (Heated Seats)................. 8W-80-21
C237............................. 8W-80-21
C237............................. 8W-80-21
C303............................. 8W-80-22
C303............................. 8W-80-22
C308............................. 8W-80-22
C308............................. 8W-80-22
C329 (Club Cab).................... 8W-80-22Component Page
C329 (Club Cab).................... 8W-80-23
C329 (Standard Cab)................ 8W-80-23
C329 (Standard Cab)................ 8W-80-23
C333 (Club Cab).................... 8W-80-23
C333 (Club Cab).................... 8W-80-23
C333 (Standard Cab)................ 8W-80-24
C333 (Standard Cab)................ 8W-80-24
C342............................. 8W-80-24
C342............................. 8W-80-24
C343............................. 8W-80-24
C343............................. 8W-80-24
C344 (Dual Rear Wheels)............. 8W-80-25
C344 (Dual Rear Wheels)............. 8W-80-25
C345............................. 8W-80-25
C345............................. 8W-80-25
C346............................. 8W-80-26
C346............................. 8W-80-26
C347............................. 8W-80-26
C347............................. 8W-80-27
C348............................. 8W-80-27
C348............................. 8W-80-28
C352............................. 8W-80-28
C352............................. 8W-80-28
C353............................. 8W-80-28
C353............................. 8W-80-28
C358............................. 8W-80-29
C358............................. 8W-80-29
C359 (Heated Seat).................. 8W-80-29
C359 (Heated Seat).................. 8W-80-29
C360 (Club Cab).................... 8W-80-30
C360 (Club Cab).................... 8W-80-30
C361............................. 8W-80-30
C361............................. 8W-80-30
C364............................. 8W-80-31
C364............................. 8W-80-31
C365 (Heated Seat).................. 8W-80-31
C365 (Heated Seat).................. 8W-80-31
Camshaft Position Sensor (8.0L Gas).... 8W-80-32
Camshaft Position Sensor (Diesel)...... 8W-80-32
Camshaft Position Sensor
(Gas Except 8.0L)................. 8W-80-32
Cargo Lamp No. 1................... 8W-80-32
Cargo Lamp No. 2................... 8W-80-32
Center High Mounted Stop Lamp No. 1 . . 8W-80-33
Center High Mounted Stop Lamp No. 2 . . 8W-80-33
Center Identification Lamp............ 8W-80-33
Central Timer Module C1............. 8W-80-33
Central Timer Module C2............. 8W-80-34
Cigar Lighter...................... 8W-80-34
Clockspring C1..................... 8W-80-34
Clockspring C2..................... 8W-80-34
Clockspring C3..................... 8W-80-35
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1

4WD SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 G107 18BK/GY 4WD SWITCH SENSE
2 Z1 18BK GROUND
A/C COMPRESSOR CLUTCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 C3 18DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT
2 Z11 18BK/WT GROUND
A/C-HEATER CONTROL - BLACK 7 WAY
CAV CIRCUIT FUNCTION
1 Z3 12BK/OR GROUND
2 C7 12BK/TN HIGH SPEED BLOWER MOTOR CONTROL
3 C6 14LB M2 SPEED BLOWER MOTOR CONTROL
4 C5 16LG M1 SPEED BLOWER MOTOR CONTROL
5 C4 16TN LOW SPEED BLOWER MOTOR CONTROL
6 C90 22LG/WT A/C SELECT INPUT
7 E2 22OR PANEL LAMPS FEED
A/C HEATER TEMPERATURE SELECT-5WAY
CAV CIRCUIT FUNCTION
1- -
2 Z2 22BK/LG GROUND
3 C82 22YL/OR TEMPERATURE SELECT
4 F15 22DB FUSED IGNITION SWITCH OUTPUT (RUN)
5- -
A/C HIGH PRESSURE SWITCH-2WAY
CAV CIRCUIT FUNCTION
1 C90 18LG/WT A/C SELECT INPUT
2 C22 18DB A/C SWITCH SENSE
8W - 80 - 4 8W-80 CONNECTOR PIN-OUTSBR/BE

POWERTRAIN CONTROL MODULE C2 (GAS) - WHITE 32 WAY
CAV CIRCUIT FUNCTION
13 K28 18GY/LB (5.9L)(8.0L) FUEL INJECTOR NO. 8 DRIVER
14 K116 18WT (8.0L) FUEL INJECTOR NO. 10 DRIVER
15 K12 18TN FUEL INJECTOR NO. 2 DRIVER
16 K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER
17 - -
18 - -
19 - -
20 - -
21 T60 18BR (A/T)(5.9L) 3-4 SHIFT SOLENOID CONTROL
22 - -
23 G60 18GY/OR ENGINE OIL PRESSURE SENSOR SIGNAL
23 G60 18GY/OR(5.9L) ENGINE OIL PRESURE SENSOR SIGNAL
24 - -
25 T13 18DB/BK (A/T)(5.9L) OUTPUT SPEED SENSOR GROUND
26 - -
27 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
28 T14 18LG/BK (A/T)(5.9L) OUTPUT SPEED SENSOR SIGNAL
29 T25 18LG/WT (A/T)(5.9L) GOVERNOR PRESSURE SENSOR SIGNAL
30 K30 18PK (A/T)(5.9L) TRANSMISSION CONTROL RELAY CONTROL
31 K7 18OR (A/T)(5.9L) 5V SUPPLY
32 - -
POWERTRAIN CONTROL MODULE C3 (DIESEL) - GRAY 32 WAY
CAV CIRCUIT FUNCTION
1 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
2- -
3 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
6- -
7- -
8- -
9- -
10 - -
11 V32 18YL/RD SPEED CONTROL SUPPLY
12 A142 14DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
13 T6 18OR/WT (A/T) OVERDRIVE OFF SWITCH SENSE
14 - -
15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
16 - -
17 - -
18 - -
19 - -
20 - -
21 - -
22 C20 18BR A/C SWITCH SENSE
23 C90 18LG/WT A/C SELECT INPUT
24 V40 18WT/PK BRAKE SWITCH SENSE
25 T125 18DB GENERATOR SOURCE
26 K226 18DB/WT FUEL LEVEL SENSOR SIGNAL
27 D21 18PK/DB SCI TRANSMIT
8W - 80 - 72 8W-80 CONNECTOR PIN-OUTSBR/BE

POWERTRAIN CONTROL MODULE C3 (DIESEL) - GRAY 32 WAY
CAV CIRCUIT FUNCTION
28 D2 18WT/BK CCD BUS(-)
29 D220 18WT/VT SCI RECEIVE
30 D1 18VT/BR CCD BUS(+)
31 - -
32 V37 18RD/LG SPEED CONTROL SWITCH SIGNAL
POWERTRAIN CONTROL MODULE C3 (GAS) - GRAY 32 WAY
CAV CIRCUIT FUNCTION
1 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
2- -
3 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
6- -
7- -
8 K199 18BR/VT(5.9L) OXYGEN SENSOR 1/1 HEATER CONTROL
8 Z11 18BK/WT(5.9HD/8.0L) OXYGEN SENSOR 1/1 HEATER CONTROL
8 K199 18BR/VT (CALIFORNIA)(5.9L) OXYGEN SENSOR 1/1 HEATER CONTROL
9 K145 20DG/PK (CALIFORNIA)(5.9L) OXYGEN SENSOR DOWNSTREAM RELAY CONTROL
10 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
11 V32 18YL/RD SPEED CONTROL SUPPLY
12 A142 14DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
13 T6 18OR/WT (A/T) OVERDRIVE OFF SWITCH SENSE
14 K107 18OR LEAK DETECTION PUMP SWITCH SENSE
15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
16 Z11 18BK/WT(5.9LHD/8.0L) No Function Defined
16 K299 18BR.WT(CALIFORNIA)(5.9L) OXYGEN SENSOR 2/1 HEATER CONTROL
16 K299 18BR/WT(5.9L) OXYGEN SENSOR 1/2 SIGNAL CONTROL
17 - -
18 - -
19 K31 18BR/WT FUEL PUMP RELAY CONTROL
20 K52 18PK/WT EVAPORATIVE EMISSION SOLENOID CONTROL
21 - -
22 C20 18BR A/C SWITCH SENSE
23 C90 18LG/WT A/C SELECT INPUT
24 V40 18WT/PK BRAKE SWITCH SENSE
25 T125 18DB GENERATOR SOURCE
26 K226 18DB/WT(CALIFORNIA)(5.9L) FUEL LEVEL SENSOR SIGNAL
27 D21 18PK/DB SCI TRANSMIT
28 D2 18WT/BK CCD BUS (-)
29 D20 18DG SCI RECEIVE
30 D1 18VT/BR CCD BUS (+)
31 - -
32 V37 18RD/LG SPEED CONTROL SWITCH SIGNAL
A8 K199 18BR/VT(5.9L) OXYGEN SENSOR 1/1 HEATER CONTROL
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73

8W-91 CONNECTOR/GROUND/SPLICE LOCATION
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION..........................1
CONNECTOR/GROUND/SPLICE
LOCATION
DESCRIPTION
This section provides illustrations identifying con-
nector, ground, and splice locations in the vehicle.Connector, ground, and splice indexes are provided.
Use the wiring diagrams in each section for connec-
tor, ground, and splice identification. Refer to the
index for the proper figure number. For items that
are not shown in this section N/S is placed in the
Fig. column.
CONNECTORS
CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
4WD Switch BK On Front Axle N/S
A/C Compressor Clutch BK Rear of A/C Compressor 7, 8, 11
A/C Heater Control BK Center of Instrument Panel 33
A/C Heater Temperature
SelectNAT Center of Instrument Panel 33
A/C High Pressure Switch BK At A/C Compressor 7, 8, 11
A/C Low Pressure Switch BK Top of A/C Accumulator 1, 3
Accelerator Pedal Position
Sensor (Diesel)Left Front of Engine 13, 14
Aftermarket Trailer Tow
ConnectorRear of Vehicle N/S
Airbag Control Module Center of I.P. at Airbag Control Module 30
Ambient Temperature Sensor BK Radiator Left Support N/S
Ash Receiver Lamp BK Center of Instrument Panel 34
Back-up Lamp Switch (M/T) BK Top of Transmission 16
Battery Temperature Sensor BK Below Battery Tray 21
Blend Door Actuator Center of Instrument Panel N/S
Blower Motor BK Bottom Right of Instrument Panel 30
Blower Motor Resistor Block BK Bottom Right of Instrument Panel 34
Brake Lamp Switch Brake Pedal Arm 30, 32
Brake Pressure Switch BK At Master Cylinder 18
Bypass Jumper (A/T) GN Top Of Clutch Pedal 35
C105 Rear of Front Bumper N/S
C106 BK Rear of Front Bumper 22
C114 BK Radiator Left Support 20
C125 (Diesel) BK Left Rear of Engine Compartment 3
BR/BE8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1

(5) After honing, it is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter-
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Recover refrigerant from a/c system, if
equipped (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(4) Remove the a/c condenser, if equipped (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - REMOVAL).
(5) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
(6) Remove the washer bottle from the fan shroud.
(7) Remove the viscous fan/drive (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(8) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(9) Remove the upper crossmember and top core
support.
(10) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).(11) Remove the A/C compressor with the lines
attached. Secure compressor out of the way.
(12) Remove generator assembly (Refer to 8 -
ELECTRICAL/CHARGING/GENERATOR - REMOV-
AL).
(13) Remove the air cleaner resonator and duct
work as an assembly.
(14) Disconnect the throttle linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL).
(15) Remove throttle body (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE BODY -
REMOVAL).
(16) Remove the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(17) Remove the distributor cap and wiring.
(18) Disconnect the heater hoses.
(19) Disconnect the power steering hoses, if
equipped.
(20) Perform the Fuel System Pressure Release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE).
(21) Disconnect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(22) On Manual Transmission vehicles, remove the
shift lever (Refer to 21 - TRANSMISSION/TRANS-
AXLE/MANUAL/SHIFT COVER - REMOVAL).
(23) Raise and support the vehicle on a hoist and
drain the engine oil.
(24) Remove engine front mount thru-bolt nuts.
(25) Disconnect the transmission oil cooler lines
from their retainers at the oil pan bolts.
(26) Disconnect exhaust pipe at manifolds.
(27) Disconnect the starter wires. Remove starter
motor (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - REMOVAL).
(28) Remove the dust shield and transmission
inspection cover.
(29) Remove drive plate to converter bolts (Auto-
matic transmission equipped vehicles).
(30) Remove transmission bell housing to engine
block bolts.
(31) Lower the vehicle.
(32) Install an engine lifting fixture.
(33) Separate engine from transmission, remove
engine from vehicle, and install engine assembly on a
repair stand.
INSTALLATION
(1) Remove engine from the repair stand and posi-
tion in the engine compartment. Position the thru-
bolt into the support cushion brackets.
(2) Install engine lifting device.
Fig. 3 Cylinder Bore Crosshatch Pattern
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
9 - 12 ENGINE 5.9LBR/BE
ENGINE 5.9L (Continued)

(3) Lower engine into compartment and align
engine with transmission:
²Manual Transmission: Align clutch disc assem-
bly (if disturbed). Install transmission input shaft
into clutch disc while mating engine and transmis-
sion surfaces. Install two transmission to engine
block mounting bolts finger tight.
²Automatic Transmission: Mate engine and trans-
mission and install two transmission to engine block
mounting bolts finger tight.
(4) Lower engine assembly until engine mount
through bolts rest in mount perches.
(5) Install remaining transmission to engine block
mounting bolts and tighten.
(6) Tighten engine mount through bolts.
(7) Install drive plate to torque converter bolts.
(Automatic transmission models)
(8) Install the dust shield and transmission cover.
(9) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(10) Install exhaust pipe to manifold.
(11) Install the transmission cooler line brackets to
the oil pan.
(12) Install the drain plug and tighten to 34 N´m
(25 ft. lbs.) torque.
(13) Lower the vehicle.
(14) Remove engine lifting fixture.
(15) On Manual Transmission vehicles, install the
shift lever (Refer to 21 - TRANSMISSION/TRANS-
AXLE/MANUAL/SHIFT COVER - INSTALLATION).
(16) Connect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(17) Connect the power steering hoses, if equipped.
(18) Connect the heater hoses.
(19) Install the distributor cap and wiring.
(20) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
(21) Using a new gasket, install throttle body
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE BODY - INSTALLATION).
(22) Connect the throttle linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - INSTALLATION).
(23) Install the air cleaner resonator and duct
work..
(24) Install the generator and wire connections
(Refer to 8 - ELECTRICAL/CHARGING/GENERA-
TOR - INSTALLATION).
(25) Install a/c compressor and lines (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - INSTALLATION).(26) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(27) Install upper radiator support crossmember.
(28) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(29) Connect the radiator lower hose.
(30) Connect the transmission oil cooler lines to
the radiator.
(31) Install the fan shroud.
(32) Install the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(33) Connect the radiator upper hose.
(34) Install the washer bottle.
(35) Install the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
INSTALLATION).
(36) Connect the transmission cooler lines.
(37) If equipped, install the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - INSTALLATION).
(38) Evacuate and charge the air conditioning sys-
tem, if equipped (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE).
(39) Add engine oil to crankcase (Refer to LUBRI-
CATION & MAINTENANCE/FLUID TYPES - SPEC-
IFICATIONS).
(40) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(41) Connect battery negative cable.
(42) Start engine and inspect for leaks.
(43) Road test vehicle.
SPECIFICATIONS
5.9L ENGINE
ENGINE SPECIFICATIONS
DESCRIPTION SPECIFICATION
GENERAL SPECIFICATIONS
Engine Type 90É V-8 OHV
Bore and Stroke 101.6 x 90.9 mm
(4.00 x 3.58 in.)
Displacement 5.9L (360 c.i.)
Compression Ratio 9.1:1
Firing Order 1±8±4±3±6±5±7±2
Lubrication Pressure Feed ± Full
Flow
BR/BEENGINE 5.9L 9 - 13
ENGINE 5.9L (Continued)