2002 DODGE RAM torque

(3) Rotate module until positioned as shown in
(Fig. 19) or (Fig. 20). This step must be performed to
prevent float from contacting side of fuel tank. Be
sure fuel filter/fuel pressure regulator is pointed to
drivers side of vehicle.
(4) Install Special Tool 6856 (Fig. 21) to locknut.
(5) Tighten locknut to 24± 44 N´m (18±32 ft. lbs.)
torque.
(6) Install fuel tank. Refer to Fuel Tank - All
Engines in the Removal/Installation section.
FUEL RAIL
DESCRIPTION
DESCRIPTION - 5.9L
The fuel injector rail is used to attach the fuel
injectors to the engine. It is mounted to the engine
(Fig. 22).
DESCRIPTION - 8.0L
The fuel injector rail is used to attach the fuel
injectors to the engine. The fuel rail supplies the nec-
essary fuel to each individual fuel injector and is
mounted to the lower half of the two-piece intake
manifold (Fig. 23). The metal, one-piece fuel rail is
not repairable.
OPERATION
OPERATION - 5.9L
High pressure from the fuel pump is routed to the
fuel rail. The fuel rail then supplies the necessary
fuel to each individual fuel injector.A fuel pressure test port is located on the fuel rail.
A quick-connect fitting with a safety latch clip is
used to attach the fuel line to the fuel rail.
Fig. 21 Locknut Removal/InstallationÐTYPICAL
1 - SPECIAL TOOL 6856
2 - LOCKNUT
Fig. 22 Fuel RailÐ5.9L EngineÐTypical
1 - FUEL RAIL CONNECTING HOSE
2 - FUEL RAIL
3 - MOUNTING BOLTS (4)
Fig. 23 Fuel RailÐ8.0L Engine
1 - FUEL RAIL
2 - ELECTRICAL CONNECTOR
3 - MOUNTING BOLTS (6)
4 - INTAKE MANIFOLD LOWER HALF
5 - FUEL PRESSURE TEST PORT
6 - FUEL INJECTORS (10)
14 - 14 FUEL DELIVERY - GASOLINEBR/BE
FUEL PUMP MODULE (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)

ule is being installed, refer to Fuel Tank Module
Removal/Installation in this group.
(2) Place fuel tank on top of transmission jack.
(3) Install rubber fill and vent lines to tank.
Tighten hose clamps to 2.3 N´m (20 in. lbs.) torque.
(4) Raise tank into position while guiding fill and
vent hoses to body. Raise tank only enough to allow
access to top of tank.
(5)Gas Powered Engines:
(a) Connect electrical connector to fuel pump
module.
(b) Connect EVAP hoses at rollover valves.
(c) Connect fuel supply line at fuel filter/fuel
pressure regulator. Refer to Quick-Connect Fittings
for procedures.
(6)Diesel Powered Engines:
(a) Connect electrical connector to fuel tank
module.
(b) Connect fuel supply and fuel return lines to
fuel tank module fittings. Refer to Quick-Connect
Fittings in this group.
(7) Connect two mounting straps and mounting
strap nuts.
(8) Tighten strap nuts to 41 N´m (30 ft. lbs.)
torque. Do not over tighten retaining strap nuts.
(9) Remove transmission jack.
(10) Connect fuel filler tube assembly to body.
(11) If equipped, connect grounding wire (strap)
and screw.
(12) Refill fuel tank and inspect all hoses and lines
for leaks.
(13) Connect negative battery cable(s) to bat-
tery(s).
FUEL TANK CHECK VALVE
DESCRIPTION
Diesel Powered Engine:One fuel tank check
valve is used. The check valve is located on the top of
the fuel tank module (Fig. 37). The valve may be ser-
viced separately.
Gasoline Powered Engines:If equipped with a
26 or 34 gallon fuel tank, two check valves are used.
One of the valves is permanently mounted to the top
of fuel tank (Fig. 38). If replacement of this particu-
lar valve is necessary, the fuel tank must be
replaced. The other check valve is located on the top
of the fuel pump module (Fig. 38). This valve may be
serviced separately. If replacement is necessary, refer
to the Removal/Installation section of this group.
If equipped with a 35 gallon fuel tank, two check
valves are used. Both valves are permanently
mounted to the top of fuel tank (Fig. 39). If replace-
ment is necessary, the fuel tank must be replaced.
Fig. 37 Check Valve LocationÐDiesel Powered
1 - AUXILIARY CAPPED FITTING
2 - FUEL PUMP MODULE
3 - FUEL SUPPLY/RETURN FITTINGS
4 - ELECTRICAL CONNECTOR
5 - LOCKNUT
6 - FUEL TANK CHECK VALVE
Fig. 38 Check Valve LocationsÐGas
1 - FUEL FILTER/PRESSURE REGULATOR
2 - FUEL SUPPLY FITTING
3 - REAR FUEL TANK CHECK VALVE
4 - ELECTRICAL CONNECTOR
5 - FUEL PUMP MODULE
6 - FRONT FUEL TANK CHECK VALVE
7 - LOCKNUT
BR/BEFUEL DELIVERY - GASOLINE 14 - 21
FUEL TANK (Continued)

FUEL INJECTION - GASOLINE
TABLE OF CONTENTS
page page
FUEL INJECTION - GASOLINE
DIAGNOSIS AND TESTING
VISUAL INSPECTIONÐ5.9L ENGINES.....29
VISUAL INSPECTIONÐ8.0L ENGINE......32
SPECIFICATIONS - TORQUE - GAS FUEL
INJECTION..........................35
SPECIAL TOOLS
FUEL SYSTEM.......................35
ACCELERATOR PEDAL
REMOVAL.............................36
INSTALLATION.........................37
CRANKSHAFT POSITION SENSOR
DESCRIPTION
DESCRIPTION - 5.9L...................37
DESCRIPTION - 8.0L...................37
OPERATION
OPERATION - 5.9L....................37
OPERATION - 8.0L....................38
REMOVAL
REMOVAL - 5.9L......................38
REMOVAL - 8.0L......................39
INSTALLATION
INSTALLATION - 5.9L..................39
INSTALLATION - 8.0L..................39
FUEL PUMP RELAY
DESCRIPTION.........................40
OPERATION...........................40
REMOVAL.............................40
INSTALLATION.........................40
IDLE AIR CONTROL MOTOR
DESCRIPTION.........................40
OPERATION...........................40
REMOVAL
REMOVAL - 5.9L......................41
REMOVAL - 8.0L......................41
INSTALLATION
INSTALLATION - 5.9L..................42
INSTALLATION - 8.0L..................42
INTAKE AIR TEMPERATURE SENSOR
DESCRIPTION - 5.9L/8.0L.................42
OPERATION - 5.9L/8.0L..................42
REMOVAL
REMOVAL - 5.9L......................42
REMOVAL - 8.0L......................43
INSTALLATION
INSTALLATION - 5.9L..................43
INSTALLATION - 8.0L..................43MANIFOLD ABSOLUTE PRESSURE SENSOR
DESCRIPTION - 5.9L/8.0L.................43
OPERATION - 5.9L/8.0L..................43
REMOVAL
REMOVAL - 5.9L......................44
REMOVAL - 8.0L......................44
INSTALLATION
INSTALLATION - 5.9L..................45
INSTALLATION - 8.0L..................45
O2 SENSOR
DESCRIPTION.........................45
OPERATION...........................45
REMOVAL.............................46
INSTALLATION.........................47
PTO SWITCH
DESCRIPTION.........................47
OPERATION...........................47
THROTTLE BODY
DESCRIPTION.........................47
OPERATION...........................47
REMOVAL
REMOVAL - 5.9L......................47
REMOVAL - 8.0L......................47
INSTALLATION
INSTALLATION - 5.9L..................48
INSTALLATION - 8.0L..................49
THROTTLE CONTROL CABLE
REMOVAL.............................49
INSTALLATION.........................50
THROTTLE POSITION SENSOR
DESCRIPTION.........................50
OPERATION...........................50
REMOVAL
REMOVAL - 5.9L......................50
REMOVAL - 8.0L......................50
INSTALLATION
INSTALLATION - 5.9L..................51
INSTALLATION - 8.0L..................51
FUEL INJECTOR
DESCRIPTION.........................52
OPERATION
OPERATION.........................52
OPERATION - PCM OUTPUT............52
DIAGNOSIS AND TESTING - FUEL INJECTOR . 53
REMOVAL.............................53
INSTALLATION.........................53
14 - 28 FUEL INJECTION - GASOLINEBR/BE

(29) Inspect transmission torque convertor housing
(automatic transmission) or clutch housing (manual
transmission) for damage to timing ring on drive
plate/flywheel.
(30) Verify that battery cable and solenoid feed
wire connections to the starter solenoid are tight and
clean. Inspect for chaffed wires or wires rubbing up
against other components.
VISUAL INSPECTIONÐ8.0L ENGINE
A visual inspection for loose, disconnected or incor-
rectly routed wires and hoses should be made. This
should be done before attempting to diagnose or ser-
vice the fuel injection system. A visual check will
help spot these faults and save unnecessary test and
diagnostic time. A thorough visual inspection will
include the following checks:
(1) Verify that the three 32±way electrical connec-
tors are fully inserted into the connector of the pow-
ertrain control module (PCM) (Fig. 12).
(2) Inspect the battery cable connections. Be sure
that they are clean and tight.
(3) Inspect fuel pump relay and air conditioning
compressor clutch relay (if equipped). Inspect the
ASD relay connections. Inspect starter motor relay
connections. Inspect relays for signs of physical dam-
age and corrosion. The relays are located in the
Power Distribution Center (PDC) (Fig. 13). Refer to
label on PDC cover for relay location.
(4) Inspect ignition coil pack primary connections.
Verify that secondary cables are firmly connected to
coils (Fig. 14).
(5) Be sure that spark plug cables are firmly con-
nected and the spark plugs are in their correct firing
order. Be sure that camshaft position sensor wire
connector is firmly connected to harness connector.
Inspect spark plug condition. Refer to 8, Ignition.Connect vehicle to an oscilloscope and inspect spark
events for fouled or damaged spark plugs or cables.
(6) Verify that generator output wire, generator
connector and ground wire are firmly connected to
the generator.
(7) Inspect the system body grounds for loose or
dirty connections. Refer to 8, Wiring for ground loca-
tions.
(8) Verify crankcase ventilation (CCV) operation.
Refer to 25, Emission Control System for additional
information.
(9) Inspect fuel tube quick-connect fitting-to-fuel
rail connections.
(10) Verify that hose connections to all ports of
vacuum fittings on intake manifold are tight and not
leaking.
Fig. 11 Oxygen SensorsFig. 12 Powertrain Control Module (PCM)
1 - PCM MOUNTING BOLTS (3)
2 - POWERTRAIN CONTROL MODULE (PCM)
3 - (3) 32±WAY CONNECTORS
Fig. 13 Power Distribution Center (PDC)
1 - POWER DISTRIBUTION CENTER (PDC)
14 - 32 FUEL INJECTION - GASOLINEBR/BE
FUEL INJECTION - GASOLINE (Continued)

(20) Raise and support the vehicle.
(21) Verify that all oxygen sensor wire connectors
are firmly connected to the sensors. Inspect sensors
and connectors for damage (Fig. 18), (Fig. 19) or (Fig.
20).
(22) Inspect for pinched or leaking fuel tubes.
Inspect for pinched, cracked or leaking fuel hoses.
(23) Inspect for exhaust system restrictions such
as pinched exhaust pipes, collapsed muffler or
plugged catalytic convertor.
(24) If equipped with automatic transmission, ver-
ify that electrical harness is firmly connected to park/
neutral switch. Refer to 21, Automatic Transmission.
(25) Verify electrical harness is firmly connected to
rear wheel speed sensor. Verify rear wheel speed sen-
sor is firmly attached to rear axle with proper air
gap. Refer to 5, Brakes for information.
(26) If equipped with 4±wheel antilock brake sys-
tem, verify electrical harness is firmly connected to
each front wheel speed sensor. Verify both front
wheel speed sensors are firmly attached. Refer to 5,
Brakes for information.
(27) Verify that fuel pump/gauge sender unit wire
connector is firmly connected to harness connector.
(28) Inspect fuel hoses at fuel pump/gauge sender
unit for cracks or leaks.
(29) Inspect transmission torque convertor housing
(automatic transmission) or clutch housing (manual
transmission) for damage to timing ring on drive
plate/flywheel.
(30) Verify that battery cable and solenoid feed
wire connections to the starter solenoid are tight and
clean. Inspect for chaffed wires or wires rubbing up
against other components.
Fig. 18 Upstream/Downstream Oxygen Sensors
1 - DOWN STREAM OXYGEN SENSOR (1/2)
2 - UP STREAM OXYGEN SENSOR (1/1)
Fig. 19 Left/Right
1 - DUAL OXYGEN SENSORS
2 - TOP OF TRANSMISSION
Fig. 20 Pre-Catalyst/Post Catalyst Oxygen Sensors
1 - POST CATALYST OXYGEN SENSOR (1/3)
2 - PRE-CATALYST OXYGEN SENSOR (1/2)
14 - 34 FUEL INJECTION - GASOLINEBR/BE
FUEL INJECTION - GASOLINE (Continued)

SPECIFICATIONS - TORQUE - GAS FUEL INJECTION
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Air Cleaner Housing
Mount. NutsÐ8.0L Engine11 9 6
Air Cleaner Housing Metal
ClampÐ5.9L Engines435
Crankshaft Position
Sensor Mounting
BoltsÐAll Engines870
Camshaft Position Sensor
MountingÐ8.0L Engine650
Engine Coolant
Temperature SensorÐAll
Engines6-8 55-75
Fuel Tank Mounting Nuts 41 30
Fuel Hose Clamps 1 10
IAC Motor-To-Throttle
Body Bolts760
Intake Manifold Air Temp.
SensorÐAll Engines12-15 110-130
MAP Sensor Mounting
ScrewsÐ5.9L Engines325
MAP Sensor Mounting
ScrewsÐ8.0L Engine220
Oxygen SensorÐAll
Engines30 22
Powertrain Control Module
Mounting Screws435
Throttle Body Mounting
BoltsÐ5.9L Engines23 200
Throttle Body Mounting
BoltsÐ8.0L Engine22 192
Throttle Position Sensor
Mounting ScrewsÐAll
Engines760
SPECIAL TOOLS
FUEL SYSTEM
Spanner WrenchÐ6856
Fitting, Air MeteringÐ6714
BR/BEFUEL INJECTION - GASOLINE 14 - 35
FUEL INJECTION - GASOLINE (Continued)

REMOVAL - 8.0L
The crankshaft position sensor is located on the
right-lower side of the cylinder block, forward of the
right engine mount, just above the oil pan rail (Fig.
27).
(1) Raise and support vehicle.
(2) Disconnect sensor pigtail harness from main
engine wiring harness.
(3) Remove sensor mounting bolt (Fig. 28).
(4) Cut plastic tie strap (Fig. 27) securing sensor
pigtail harness to side of engine block.
(5) Carefully pry sensor from cylinder block in a
rocking action with two small screwdrivers.
(6) Remove sensor from vehicle.
(7) Check condition of sensor o-ring (Fig. 29).
INSTALLATION
INSTALLATION - 5.9L
(1) Position crankshaft position sensor to engine.
(2) Install mounting bolts and tighten to 8 N´m (70
in. lbs.) torque.
(3) Connect main harness electrical connector to
sensor.
(4) Install air cleaner tube.
INSTALLATION - 8.0L
The crankshaft position sensor is located on the
right-lower side of the cylinder block, forward of the
right engine mount, just above the oil pan rail (Fig.
27).
(1) Apply a small amount of engine oil to sensor
o-ring (Fig. 29).
(2) Install sensor into cylinder block with a slight
rocking action. Do not twist sensor into position as
damage to o-ring may result.
Fig. 27 Crankshaft Position Sensor LocationÐ8.0L
V-10 Engine
1 - CRANKSHAFT POSITION SENSOR
2 - HOLE
3 - OIL FILTER
4 - PLASTIC TIE STRAP
5 - PIGTAIL HARNESS
Fig. 28 Sensor Removal/InstallationÐ8.0L V-10
Engine
1 - CRANKSHAFT POSITION SENSOR
2 - MOUNTING BOLT
3 - SENSOR POSITIONED FLUSH TO CYLINDER BLOCK
Fig. 29 Sensor O-RingÐ8.0L V-10 Engine
1 - CRANKSHAFT POSITION SENSOR O-RING
2 - ELECTRICAL CONNECTOR
3 - PIGTAIL HARNESS
BR/BEFUEL INJECTION - GASOLINE 14 - 39
CRANKSHAFT POSITION SENSOR (Continued)