2002 DODGE RAM injector

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

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Engine Oil Pressure Sensor
(V8)BK Near Distributor 5
Engine Oil Pressure Sensor
(V10)Near Oil Filter 8
Engine Oil Pressure Sensor
(Diesel)Left Side of Engine 15
Fuel Heater (Diesel) Left Side of Engine 13
Fuel Injection Pump (Diesel) Left Side of Engine, Below ECM 13
Fuel Injector No.1 BK At Fuel Injector 7
Fuel Injector No. 2 BK At Fuel Injector 7, 8
Fuel Injector No. 3 BK At Fuel Injector 7, 8
Fuel Injector No. 4 BK At Fuel Injector 7, 8
Fuel Injector No. 5 BK At Fuel Injector 7, 8
Fuel Injector No. 6 BK At Fuel Injector 7, 8
Fuel Injector No. 7 BK At Fuel Injector 7, 8
Fuel Injector No. 8 BK At Fuel Injector 7, 8
Fuel Injector No. 9 BK At Fuel Injector 8
Fuel Injector No. 10 BK At Fuel Injector 8
Fuel Pump Module (Gas) LTGY At Frame Rail 29
Fuel Tank Module (Diesel) LTGY At Frame Rail N/S
Fuel Transfer Pump (Diesel) Left Rear of Engine Bottom of Pump 13
Generator BK Front of Engine 10, 11
Glove Box Lamp At Glove Box 30
Headlamp Switch C1 BK Left Side of Instrument Panel 30, 34
Headlamp Switch C2 Left Side of Instrument Panel 30, 34
Heated Mirror Switch Center of Instrument Panel 33
High Note Horn BK Front Bumper Right Support 22
Idle Air Control Motor BK On Throttle Body 12
Ignition Coil (5.9L) GY Right Front of Engine 7, 12
Ignition Coil 4 Pack (8.0L) BK Right Side of Engine 12
Ignition Coil 6 Pack (8.0L) BK Right Side of Engine 12
Ignition Switch C1 BK Steering Column 32
Ignition Switch C2 GY Steering Column 32
Instrument Cluster C1 Rear of Instrument Cluster 30
Instrument Cluster C2 Rear of Instrument Cluster 30
Intake Air Heater Relay
(Diesel)Left Fender Side Shield 21
Intake Air Temperature
Sensor (Diesel)Left Rear of Engine 13
Intake Air Temperature
Sensor (Gas)BK On Intake Manifold 7, 8
Joint Connector No. 1 In Power Distribution Center N/S
Joint Connector No. 2 In Power Distribution Center N/S
8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONBR/BE
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

GROUND
NUMBERLOCATION FIG.
G200 Left Cowl 32
G201 Instrument Panel Right Center Support 30, 33
G300 Left Lower Cowl 25
G301 Below Left Rear Speaker 23
G302 At Overhead Console 25
SPLICES
SPLICE
NUMBERLOCATION FIG.
S100 Engine Harness Near T/O to Oil Pressure Sensor 7
S102 Headlamp and Dash Harness, Near T/O to Right Park/Turn Lamp 22
S103 Headlamp and Dash Harness, Near T/O to Left Park/Turn Lamp N/S
S104 Headlamp and Dash Harness, Near T/O to Left Front Headlamp N/S
S105 Headlamp and Dash Harness, In Power Distribution Center 19
S106 Headlamp and Dash Harness, In Power Distribution Center 19
S107 Headlamp and Dash Harness, Near Left Wheel Speed Sensor 19
S108 Headlamp and Dash Harness, Near Daytime Running Lamp Module 19
S109 Battery Harness, In T/O for Engine and Transmission Ground N/S
S110 Headlamp and Dash Harness, Near Left Wheel Speed Sensor 19
S111 Transmission Harness Near T/O to A/C Low Pressure Switch 4
S112 Headlamp and Dash Harness, Near Antilock Brake Controller 19
S113 Headlamp and Dash Harness, Near Antilock Brake Controller 19
S114 Headlamp and Dash Harness, In T/O to Chassis Harness 19
S116(V8) Engine Harness, Near T/O to Fuel Injectors 2
S116 (V10) Engine Harness Rear of Engine 2, 9
S116 (Diesel) Transmission Harness, In T/O to Power Distribution Center 4
S117 (V8) Engine Harness, Near T/O to Fuel Injectors 2
S117 (V10) Engine Harness, Near T/O to fuel Injector No. 8 2, 9
S118 (V8) Engine Harness, Near T/O to Fuel Injectors 2
S118 (V10) Engine Harness, Rear of Engine 2, 9
S119 (V8) Engine Harness, Near T/O to Fuel Injectors 2
S119 (V10) Engine Harness, Rear of Engine 2, 9
S120 (V8) Engine Harness, Near T/O to Fuel Injectors 2
S120 (V10) Engine Harness, Rear of Engine 2, 9, 17
S120 (Diesel) Transmission Harness, Near T/O to A/C Low Pressure Switch 4
S121 (V8) Engine Harness, Near T/O to Fuel Injector No. 5 7
S121 (V10) Engine Harness, Near T/O to Fuel Injector No. 7 9
S122 (V8) Engine Harness, Top of Transmission 6
S122 (V10) Engine Harness, In T/O to Transmission N/S
S123 (V8) Engine Harness, Near T/O to Fuel Injector No. 3 7
S123 (V10) Engine Harness, Near T/O to Fuel Injector No. 3 9
BR/BE8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICE
NUMBERLOCATION FIG.
S124 (V8) Engine Harness, Top of Transmission 6
S124 (V10) Engine Harness, In T/O to Transmission N/S
S126 (V8) Engine Harness, Near T/O to Fuel Injector No. 1 7
S126 (V10) Engine Harness, Near T/O to Engine Ground 9, 17
S126 (Diesel) Transmission Harness, Near T/O to Powertrain Control Module 4
S127 (V8) Engine Harness, on Top of Transmission 6
S127 (V10) Engine Harness, Near T/O to Transmission 17
S127 (Diesel) Transmission Harness, Near T/O to A/C Low Pressure Switch 4
S128 (Diesel) Transmission Harness, Near T/O to Power Distribution Center 4
S130 (V8) Engine Harness, Near T/O to Oil Pressure Sensor 7
S131 (V10) Engine Harness, Rear of Engine 9
S134 Fog Lamp Harness, In T/O to Right Fog Lamp N/S
S136 Fog Lamp Harness, In T/O to Right Fog Lamp N/S
S141 Headlamp and Dash Harness, Near T/O to Joint Connector No. 3 22
S143 Headlamp and Dash Harness, Near T/O to Power Distribution
Center19
S144 Headlamp and Dash Harness, Near T/O to Joint Connector No. 3 22
S150 Front Bumper Right Support 22
S151 Left Front Engine Compartment 21
S152 Near Left Front Wheel Speed Sensor
S160 (Diesel) Engine Harness, Near Fuel Transfer Pump N/S
S161 (Diesel) Transmission Harness, In T/O to Power Distribution Center 4
S164 (Diesel) Engine Harness, Near Fuel Transfer Pump N/S
S165 (Diesel) Engine Harness, Near Engine Control Module N/S
S166 (Diesel) Engine Harness, Near Engine Control Module N/S
S167 (Diesel) Engine Harness, Near Fuel Transfer Pump N/S
S168 (Diesel) Engine Harness, Near T/O to Engine Coolant Temoerature Sensor N/S
S170 (Diesel) Engine Harness, In T/O to Engine Control Module N/S
S171 Transmission Harness, In T/O to Power Distribution Cente 4
S172 (Diesel) Transmission Harness, Near T/O to A/C Low Pressure Switch 4
S173 (Diesel) Transmission Harness, Near T/O to A/C Low Pressure Switch 4
S174 (Diesel) Transmission Harness, In T/O to Power Distribution Center 4
S175 Transmission Harness, In T/O to Power Distribution Center 4
S176 Headlamp and Dash Harness, In Power Distribution Center 19
S177 Headlamp and Dash Harness, In T/O to Daytime Running Lamps
Module19
S179 Transmission Harness, In T/O to Power Distribution Center 4
S180 Headlamp and Dash Harness, Near Intake Air Heater Relay 22
S181 Headlamp and Dash Harness, Near Intake Air Heater Relay 22
S182 Headlamp and Dash Harness, In T/O to Daytime Running Lamps
Module19
S183 Headlamp and Dash Harness, In Power Distribution Center 19
8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONBR/BE
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - PERFORMANCE
PERFORMANCE DIAGNOSIS CHARTÐGASOLINE ENGINES
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. (Refer to
8 - ELECTRICAL/BATTERY
SYSTEM/BATTERY - STANDARD
PROCEDURE). Check charging
system. (Refer to 8 - ELECTRICAL/
CHARGING - DIAGNOSIS AND
TESTING).
2. Corroded or loose battery
connections2. Clean/tighten suspect battery/
starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. (Refer to
8 - ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Seized accessory drive
component4. Remove accessory drive belt and
attempt to start engine. If engine
starts, repair/replace seized
component.
5. Engine internal mechanical
failure or hydro-static lock5. Refer to (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
ENGINE CRANKS BUT WILL NOT
START1. No spark 1. Check for spark. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- DESCRIPTION)
2. No fuel 2. Perform fuel pressure test, and if
necessary, inspect fuel injector(s)
and driver circuits. (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/
FUEL PUMP - DIAGNOSIS AND
TESTING).
3. Low or no engine compression 3. Perform cylinder compression
pressure test. (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING).
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/
DISTRIBUTOR - REMOVAL).
3. Worn or incorrect gapped spark
plugs3. Clean plugs and set gap. (Refer
to 8 - ELECTRICAL/IGNITION
CONTROL/SPARK PLUG -
CLEANING).
4. Dirt or water in fuel system 4. Clean system and replace fuel
filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
9 - 4 ENGINE 5.9LBR/BE
ENGINE 5.9L (Continued)

(2) Position the oil pump cover onto the pump
body. Tighten cover bolts to 11 N´m (95 in. lbs.)
torque.
(3) Install the relief valve and spring. Insert the
cotter pin.
(4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling
rotor cavity with engine oil.
INSTALLATION
(1) Install oil pump. During installation slowly
rotate pump body to ensure driveshaft-to-pump rotor
shaft engagement.
(2) Hold the oil pump base flush against mating
surface on No.5 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41
N´m (30 ft. lbs.) torque.
(3) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
INTAKE MANIFOLD
DESCRIPTION
The aluminum intake manifold (Fig. 64) is a single
plane design with equal length runners and uses a
separate plenum, therefore the manifold does have a
plenum gasket. It also uses separate flange gaskets
and front and rear cross-over gaskets. Extreme care
must be used when sealing the gaskets to ensure
that excess sealant does not enter the intake runners
causing a restriction. Whenever the intake manifold
is removed inspect the plenum pan for evidence of
excess oil buildup, this condition indicates that the
plenum pan gasket is leaking.
OPERATION
The intake manifold, meters and delivers air to the
combustion chambers allowing the fuel delivered by
the fuel injectors to ignite, thus producing power.
DIAGNOSIS AND TESTINGÐINTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS, OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.(3) If a change in RPMs occur, the area of the sus-
pected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - REMOVAL).
(4) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(5) Remove the accessory drive bracket.
(6) Remove the air cleaner.
(7) Perform the Fuel System Pressure release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel lines (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect the accelerator linkage (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL) and if so equipped,
the speed control and transmission kickdown cables.
(9) Remove the return spring.
(10) Remove the distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect the heat indicator sending unit
wire.
Fig. 64 Intake Manifold and Throttle BodyÐV-8 Gas
Engines Typical
1 - FUEL RAIL ASSEMBLY
2 - FUEL RAIL MOUNTING BOLTS
3 - FUEL RAIL CONNECTING HOSES
9 - 50 ENGINE 5.9LBR/BE
OIL PUMP (Continued)

DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - PERFORMANCE
PERFORMANCE DIAGNOSIS CHARTÐGASOLINE ENGINES
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. (Refer to
8 - ELECTRICAL/BATTERY
SYSTEM/BATTERY - STANDARD
PROCEDURE). Check charging
system. (Refer to 8 - ELECTRICAL/
CHARGING - DIAGNOSIS AND
TESTING).
2. Corroded or loose battery
connections2. Clean/tighten suspect battery/
starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. (Refer to
8 - ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Seized accessory drive
component4. Remove accessory drive belt and
attempt to start engine. If engine
starts, repair/replace seized
component.
5. Engine internal mechanical
failure or hydro-static lock5. Refer to (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
ENGINE CRANKS BUT WILL NOT
START1. No spark 1. Check for spark. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- DESCRIPTION)
2. No fuel 2. Perform fuel pressure test, and if
necessary, inspect fuel injector(s)
and driver circuits. (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/
FUEL PUMP - DIAGNOSIS AND
TESTING).
3. Low or no engine compression 3. Perform cylinder compression
pressure test. (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING).
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/
DISTRIBUTOR - REMOVAL).
3. Worn or incorrect gapped spark
plugs3. Clean plugs and set gap. (Refer
to 8 - ELECTRICAL/IGNITION
CONTROL/SPARK PLUG -
CLEANING).
4. Dirt or water in fuel system 4. Clean system and replace fuel
filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
BR/BEENGINE 8.0L 9 - 59
ENGINE 8.0L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL
PRESSURE TOO HIGH1. Pressure switch/gauge not
operating properly.1. Verify pressure switch is functioning
correctly. If not, replace switch/gauge.
2. Engine running to cold. 2. Refer to Coolant Temperature Below
Normal (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
3. Oil viscosity too thick. 3. Make sure the correct oil is being used.
(Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
4. Oil pressure relief valve stuck
closed or binding4. Check and replace valve.
LUBRICATING OIL LOSS 1. External leaks. 1. Visually inspect for oil leaks. Repair as
required.
2. Crankcase being overfilled. 2. Verify that the correct dipstick is being
used.
3. Incorrect oil specification or
viscosity.3. (a) Make sure the correct oil is being
used (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(b) Look for reduced viscosity from dilution
with fuel.
(c) Review/reduce oil change intervals.
4. Oil cooler leak 4. Check and replace the oil cooler.
5. High blow-by forcing oil out the
breather.5. Check the breather tube area for signs of
oil loss. Perform the required repairs.
6. Turbocharger leaking oil to the air
intake.6. Inspect the air ducts for evidence of oil
transfer. Repair as required.
7. Piston rings not sealing (oil being
consumed by the engine).7. Perform blow-by check. Repair as
required.
COMPRESSION KNOCKS 1. Air in the fuel system. 1. Bleed the fuel system (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
2. Poor quality fuel or water/gasoline
contaminated fuel.2. Verify by operating from a temporary
tank with good fuel. Clean and flush the
fuel tank. Replace fuel/water separator filter.
3. Engine overloaded. 3. Verify the engine load rating is not being
exceeded.
4. Incorrect injection pump timing. 4. Check injection pump for proper
installation.
5. Improperly operating injectors. 5. Check and replace inoperative injectors.
EXCESSIVE VIBRATION 1. Loose or broken engine mounts. 1. Replace engine mounts.
2. Damaged fan or improperly
operating accessories.2. Check and replace the vibrating
components.
3. Improperly operating vibration
damper3. Inspect/replace vibration damper.
BR/BEENGINE 5.9L DIESEL 9 - 117
ENGINE 5.9L DIESEL (Continued)