2002 DODGE RAM ignition

(2) Tighten bolts to 7 N´m (60 in. lbs.) torque.
(3) Manually operate the throttle control lever by
hand to check for any binding of the TPS.
(4) Connect TPS electrical connector to TPS.
(5) Install air cleaner housing to throttle body.
(6) Install 4 air cleaner housing mounting nuts.
Tighten nuts to 11 N´m (96 in. lbs.) torque.
(7) Install air cleaner housing cover.
(8) Install air intake tube to cover.
FUEL INJECTOR
DESCRIPTION
A separate fuel injector (Fig. 50) is used for each
individual cylinder.
OPERATION
OPERATION
The fuel injectors are electrical solenoids. The
injector contains a pintle that closes off an orifice at
the nozzle end. When electric current is supplied to
the injector, the armature and needle move a short
distance against a spring, allowing fuel to flow out
the orifice. Because the fuel is under high pressure, a
fine spray is developed in the shape of a pencil
stream. The spraying action atomizes the fuel, add-
ing it to the air entering the combustion chamber.
An individual fuel injector is used for each individ-
ual cylinder. The top (fuel entry) end of the injector is
attached into an opening on the fuel rail.The nozzle (outlet) ends of the injectors are posi-
tioned into openings in the intake manifold just
above the intake valve ports of the cylinder head.
The engine wiring harness connector for each fuel
injector is equipped with an attached numerical tag
(INJ 1, INJ 2 etc.). This is used to identify each fuel
injector.
The injectors are energized individually in a
sequential order by the Powertrain Control Module
(PCM). The PCM will adjust injector pulse width by
switching the ground path to each individual injector
on and off. Injector pulse width is the period of time
that the injector is energized. The PCM will adjust
injector pulse width based on various inputs it
receives.
Battery voltage is supplied to the injectors through
the ASD relay.
The PCM determines injector pulse width based on
various inputs.
OPERATION - PCM OUTPUT
The nozzle ends of the injectors are positioned into
openings in the intake manifold just above the intake
valve ports of the cylinder head. The engine wiring
harness connector for each fuel injector is equipped
with an attached numerical tag (INJ 1, INJ 2 etc.).
This is used to identify each fuel injector with its
respective cylinder number.
The injectors are energized individually in a
sequential order by the Powertrain Control Module
(PCM). The PCM will adjust injector pulse width by
switching the ground path to each individual injector
on and off. Injector pulse width is the period of time
that the injector is energized. The PCM will adjust
injector pulse width based on various inputs it
receives.
Battery voltage (12 volts +) is supplied to the injec-
tors through the ASD relay. The ASD relay will shut-
down the 12 volt power source to the fuel injectors if
the PCM senses the ignition is on, but the engine is
not running. This occurs after the engine has not
been running for approximately 1.8 seconds.
The PCM determines injector on-time (pulse width)
based on various inputs.
Fig. 50 Fuel Injector
1 - FUEL INJECTOR
2 - NOZZLE
3 - TOP (FUEL ENTRY)
14 - 52 FUEL INJECTION - GASOLINEBR/BE
THROTTLE POSITION SENSOR (Continued)

REMOVAL
Refer to maintenance schedules in this manual for
recommended fuel filter replacement intervals.
Draining water from fuel filter/water separa-
tor housing:
The housing drain valve (Fig. 14) serves two pur-
poses. One is topartiallydrain filter housing of
excess water. The other is tocompletelydrain hous-
ing for fuel filter, drain valve, heater element or
water-in-fuel sensor replacement.
The filter housing should be partially drained
whenever water-in-fuel warning lamp remains illumi-
nated. (Note that lamp will be illuminated for
approximately two seconds when ignition key is ini-
tially placed in ON position for a bulb check).
(1) A drain hose is located at bottom of drain valve
(Fig. 14). Place drain pan under drain hose.
(2)With engine not running,pull drain valve
handle upward to OPEN (DRAIN) position (Fig. 14).
Hold drain valve open until all water and contami-
nants have been removed and clean fuel exits drain
hose.
(3) If drain valve, fuel heater element or Water-In-
Fuel (WIF) sensor is being replaced, drain housing
completely. Dispose of mixture in drain pan according
to applicable regulations.
(4) After draining operation, push valve handle
downward to CLOSE position (Fig. 14).
(5)Fuel Filter Replacement:The fuel filter is
located inside of the fuel filter housing (Fig. 15).
(a) Unscrew and remove fuel filter cap at top of
fuel filter housing (Fig. 14). To unscrew, attach tool
to 6±sided hex center of cap. Do not attempt to
loosen cap at outer edge. The fuel filter cap is
designed to remove filter while pulling up on cap.
(b) Remove o-ring (Fig. 15) from filter cap and
discard.
(c) The filter is retained to the cap with a series
of locking fingers. Carefully pry back a few of the
fingers to unlock filter from cap.
(6)Water-In-Fuel (WIF) Sensor Replacement:
The WIF sensor is located on the side of the fuel fil-
ter housing (Fig. 15).
(a) Disconnect electrical connector at sensor
(Fig. 16).
(b) Unscrew sensor from filter housing.
Fig. 14 Water Drain Valve and Drain Hose
1 - FUEL FILTER CAP
2 - DRAIN VALVE HANDLE
3 - DRAIN HOSE
4 - FUEL FILTER/WATER SEPARATOR
Fig. 15 Fuel Filter/Water Separator Components
1 - CAP
2 - O-RING
3 - FUEL FILTER
4 - FUEL HEATER ELEMENT
5 - HOUSING
6 - O-RINGS
7 - DRAIN VALVE
8 - FUEL HEATER THERMOSTAT
9 - WATER-IN-FUEL SENSOR
14 - 64 FUEL DELIVERY - DIESELBR/BE
FUEL FILTER / WATER SEPARATOR (Continued)

(d) Tighten sensor to 2±3 N´m (15±20 in. lbs.)
torque.
(e) Connect electrical connector to WIF sensor.
(f) Install fuel filter. Refer to previous steps.
(4)Fuel Heater Element:
(a) Do not install fuel filter until heater element
is installed.
(b) Position heater element into filter housing
(fingers downward). Lock fingers into housing.
(c) Install new o-ring to electrical connector
(where connector passes through filter housing).
Apply a light film of clean diesel oil to o-ring seal.
Press this connector into filter housing until it
snaps into heater element.
(d) Install temperature sensor housing and 2
mounting screws to fuel filter housing.
(e) Connect electrical connector.
(f) Install fuel filter. Refer to previous steps.
(5)Drain Valve:
(a) Install 2 new o-rings to valve and filter hous-
ing.
(b) Apply a light film of clean diesel oil to both
seals.
(c) Position valve to filter housing.
(d) Install 4 mounting screws and tighten to 3±5
N´m (30±40 in. lbs.) torque.
(e) Connect drain hose to drain valve.
(f) Install fuel filter. Refer to previous steps.
(6) Start engine and check for leaks.
FUEL HEATER
DESCRIPTION
The fuel heater assembly is located on the side of
the fuel filter housing (Fig. 18).
The heater/element assembly is equipped with a
temperature sensor (thermostat) that senses fuel
temperature. This sensor is attached to the fuel heat-
er/element assembly.
OPERATION
The fuel heater is used to prevent diesel fuel from
waxing during cold weather operation.
When the temperature is below 45  8 degrees F,
the temperature sensor allows current to flow to the
heater element warming the fuel. When the temper-
ature is above 75  8 degrees F, the sensor stops cur-
rent flow to the heater element.
Battery voltage to operate the fuel heater element
is supplied from the ignition switch and through the
fuel heater relay. Also refer to Fuel Heater Relay.
The fuel heater element and fuel heater relay
are not computer controlled.
The heater element operates on 12 volts, 300 watts
at 0 degrees F.
DIAGNOSIS AND TESTING - FUEL HEATER
The fuel heater is used to prevent diesel fuel from
waxing during cold weather operation.
NOTE: The fuel heater element, fuel heater relay
and fuel heater temperature sensor are not con-
trolled by the Powertrain Control Module (PCM).
A malfunctioning fuel heater can cause a wax
build-up in the fuel filter/water separator. Wax
build-up in the filter/separator can cause engine
starting problems and prevent the engine from rev-
ving up. It can also cause blue or white fog-like
exhaust. If the heater is not operating in cold tem-
peratures, the engine may not operate due to fuel
waxing.
The fuel heater assembly is located on the side of
the fuel filter housing (Fig. 19).
The heater assembly is equipped with a built-in
fuel temperature sensor (thermostat) that senses fuel
temperature. When fuel temperature drops below 45
degrees   8 degrees F, the sensor allows current to
flow to the built-in heater element to warm the fuel.
When fuel temperature rises above 75 degrees   8
degrees F, the sensor stops current flow to the heater
element (circuit is open).
Fig. 18 Fuel Heater Location
1 - FUEL HEATER AND TEMP. SENSOR
2 - FUEL FILTER/WATER SEPARATOR
3 - FUEL HEATER ELECTRICAL CONNECTOR
14 - 66 FUEL DELIVERY - DIESELBR/BE
FUEL FILTER / WATER SEPARATOR (Continued)

Voltage to operate the fuel heater element is sup-
plied from the ignition switch, through the fuel
heater relay (also refer to Fuel Heater Relay), to the
fuel temperature sensor and on to the fuel heater ele-
ment.
The heater element operates on 12 volts, 300 watts
at 0 degrees F. As temperature increases, power
requirements decrease.
A minimum of 7 volts is required to operate the
fuel heater. The resistance value of the heater ele-
ment is less than 1 ohm (cold) and up to 1000 ohms
warm.
TESTING
(1) Disconnect electrical connector at sensor (Fig.
19).
Turn key to ON position. 12 volts should be
present at red wire. If not, check fuel heater relay
and related wiring. Refer to Relay TestÐFuel Heater.
If OK, proceed.
Turn key OFF. Check black wire in connector for
ground continuity with an ohmmeter. If continuity is
not present, correct open ground circuit. This test can
also be performed with a voltmeter by backprobing
black wire with it connected to sensor. Reconnect elec-
trical connector and turn key ON. Voltage drop should
not exceed 2 volts (2 volts lower than checked at 12V+
connector). If voltage is lower, check for dirty or cor-
roded ground connection and repair. If OK, proceed.
(2) With electrical connector disconnected at sen-
sor and key OFF, check electrical/mechanical opera-
tion of fuel temperature sensor. Proceed to next step:
(3) Using an ohmmeter, check for continuity across
two terminals in electrical connector at side of sen-
sor. Sensor circuit should be open if fuel temperature
has risen above 75 degrees   8 degrees F. Sensor cir-
cuit should be closed if fuel temperature has dropped
below 45 degrees   8 degrees F. If not, replace fuel
heater assembly. This same test can also be per-
formed using a voltmeter, with key ON, and by back-
probing connector.
REMOVAL/INSTALLATION
The fuel heater/element/sensor assembly is located
inside of the fuel filter housing. Refer to Fuel Filter/
Water Separator Removal/Installation for procedures.
FUEL HEATER RELAY
DESCRIPTION
The fuel heater relay is located in Power Distribu-
tion Center (PDC) (Fig. 20). Refer to label on inside
of PDC cover for relay location.
OPERATION
Battery voltage to operate the fuel heater element
is supplied from the ignition switch through the fuel
heater relay.The fuel heater element and fuel
heater relay are not computer controlled.
Fig. 19 Fuel Heater Location
1 - FUEL HEATER AND TEMP. SENSOR
2 - FUEL FILTER/WATER SEPARATOR
3 - FUEL HEATER ELECTRICAL CONNECTOR
Fig. 20 Power Distribution Center Location
1 - CLIP
2 - BATTERY
3 - TRAY
4 - NEGATIVE CABLE
5 - POSITIVE CABLE
6 - CLIP
7 - FENDER INNER SHIELD
8 - POWER DISTRIBUTION CENTER
BR/BEFUEL DELIVERY - DIESEL 14 - 67
FUEL HEATER (Continued)

WATER IN FUEL SENSOR
DESCRIPTION
The WIF sensor is located on the side of the fuel
filter/water separator canister (Fig. 68).
OPERATION
The sensor sends an input to the Engine Control
Module (ECM) when it senses water in the fuel filter/
water separator. As the water level in the filter/sep-
arator increases, the resistance across the WIF
sensor decreases. This decrease in resistance is sent
as a signal to the ECM and compared to a high
water standard value. Once the value reaches 30 to
40 kilohms, the ECM will activate the water-in-fuel
warning lamp through CCD bus circuits. This all
takes place when the ignition key is initially put in
the ON position. The ECM continues to monitor the
input at the end of the intake manifold air heater
post-heat cycle.
REMOVAL
The Water-In-Fuel (WIF) sensor is located at the
side of fuel filter/water separator canister. Refer to
Fuel Filter/Water Separator Removal/Installation for
WIF sensor removal/installation procedures.
FUEL DRAIN MANIFOLD
DESCRIPTION
The fuel drain manifold is actually a rifled passage
within the cylinder head (Fig. 69).
OPERATION
When the engine is running, and during injection,
a small amount of fuel flows past the injector nozzle
and is not injected into the combustion chamber. This
fuel is used to lubricate the fuel injectors. Excess fuel
drains into the fuel drain manifold (or passage). Fuel
is drained from this passage into a line at the rear of
the cylinder head (Fig. 69). After exiting the cylinder
head, fuel is routed (returned) back to the fuel tank.
A ªTº is installed into the fuel return line (Fig. 69).
This ªTº is used to allow excess fuel from the injec-
tion pump to be returned into the fuel tank. A one-
way check valve within the overflow valve prevents
fuel (from the fuel drain manifold) from entering the
fuel injection pump.
Asmallamount of fuel is returned from the fuel
injectors, while alargeamount (about 70% of sup-
plied fuel) is returned from the fuel injection pump.
Fig. 68 Water-in-Fuel Sensor Location
1 - WATER-IN-FUEL (WIF) SENSOR
2 - FUEL FILTER/WATER SEPARATOR
3 - WIF SENSOR CONNECTOR
Fig. 69 Fuel Drain Manifold Passage
1 - REAR OF CYLINDER HEAD
2 - BANJO FITTING/BOLT
3 - FUEL RETURN TO TANK
4 - FUEL RETURN LINES
5 - FUEL RETURN LINE FROM PUMP OVERFLOW VALVE
6 - FUEL DRAIN MANIFOLD PASSAGE
7 - ªTº
BR/BEFUEL DELIVERY - DIESEL 14 - 89

COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION..........................6
OPERATION
SERVICE PRECAUTIONS................6
REMOVAL.............................6
INSTALLATION..........................8
SPECIFICATIONS
TORQUE CHART......................9
KEY-IN IGNITION SWITCH
DESCRIPTION..........................9
DIAGNOSIS AND TESTING - IGNITION
SWITCH AND KEY LOCK CYLINDER.......9
LOCK CYLINDER
REMOVAL.............................10INSTALLATION.........................10
IGNITION SWITCH
DESCRIPTION.........................11
OPERATION...........................11
DIAGNOSIS AND TESTING - IGNITION
SWITCH.............................11
REMOVAL.............................12
INSTALLATION.........................12
GEAR SHIFT LEVER
REMOVAL.............................14
INSTALLATION.........................15
STEERING WHEEL
REMOVAL.............................15
INSTALLATION.........................15
COLUMN
DESCRIPTION
The tilt and standard column (Fig. 1) has been
designed to be serviced as an assembly; less wiring,
switches, shrouds, steering wheel, etc. Most steering
column components can be serviced without remov-
ing the steering column from the vehicle.
OPERATION
SERVICE PRECAUTIONS
Safety goggles should be worn at all times when
working on steering columns.
To service the steering wheel, switches or the air-
bag, refer to the WARNINGS and CAUTIONS below.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Do not hammer on steering column shaft
or shift tube. This may cause the shaft/shift tube to
collapse or damage the bearing.
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Do not
remove shaft lock plate, plate retainer, park lock
link or slider. This will damage the column (Fig. 2)
and (Fig. 3).
REMOVAL
(1) Position the front wheels straight ahead.
(2) Disconnect the negative (ground) cable from
the battery.
(3) Remove the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(4) Remove the steering wheel with an appropriate
puller,(Refer to 19 - STEERING/COLUMN/STEER-
ING WHEEL - REMOVAL).
19 - 6 COLUMNBR/BE

CAUTION: Ensure the puller bolts are fully engaged
into the steering wheel and not into the clock-
spring, before attempting to remove the wheel. Fail-
ure to do so may damage the steering wheel.
(5) Remove the shift link rod in the engine com-
partment (if equipped). Pry the rod out from the
grommet in the shift lever.
(6) Scribe or paint reference mark on the column
shaft-to-coupler. This will aid in column shaft instal-
lation alignment. Remove the steering column shaft-
to-coupler bolt (Fig. 4).
(7) Remove the steering column opening cover/
knee blocker, (Refer to 23 - BODY/INSTRUMENT
PANEL/STEERING COLUMN OPENING COVER -
REMOVAL).
Fig. 1 Steering Column
1 - STEERING WHEEL
2 - TILT LEVER
3 - UPPER SHROUD
4 - PANEL BRACKET
5 - SPACER
6 - TOE PLATE
7 - NUT
8 - LOWER SHROUD
9 - CLOCK SPRING
10 - NUT
Fig. 2 Observe Cautions
1 - CAUTION: NEVER REMOVE IGNITION LOCKING LINK
2 - CAUTION: NEVER REMOVE PARK LOCK SLIDER
3 - CAUTION: NEVER REMOVE SHAFT LOCK PLATE
Fig. 3 Observe Cautions
1 - CAUTION: NEVER REMOVE SHAFT LOCK PLATE RETAINER
Fig. 4 Steering Coupler-Typical
1 - STEERING COUPLER
2 - STEERING COLUMN
3 - SHIFT LEVER
BR/BECOLUMN 19 - 7
COLUMN (Continued)

(8) Remove the PRNDL cable on column shift vehi-
cles. Put the shift lever inParkposition. Pull the
cable and twist to remove from the position arm.
Push the tab up on bottom of the cable retainer, then
squeeze sides to remove retainer from the column
(Fig. 5).
(9) Remove the tilt lever (if equipped) from the col-
umn.
(10) Remove the upper and lower lock housing
shroud and remove the lower fixed shroud.
(11) Remove the turn signal multi-function switch
connector with a 7mm socket (Fig. 6).(12) Loosen the upper Support Bracket nuts to
allow some slack. This will aid in removal of the
upper fixed shroud.
(13) Remove the electrical connections from Key-in
light, Ignition Switch, Horn, Overdrive Switch and
Clock Spring (Speed Control) (Fig. 7).
(14) Remove the wiring harness from the column
by prying out the plastic retainer buttons.
(15) Remove the toe plate fasteners.
(16) Remove the column from vehicle.
(17) Remove the Ignition and Multi-Function
Switch, then remove the Clock Spring and tape the
Clock Spring to prevent it from turning, (Refer to 8 -
ELECTRICAL/RESTRAINTS/CLOCKSPRING -
REMOVAL).
INSTALLATION
(1) Install the clock spring and switches, (Refer to
8 - ELECTRICAL/RESTRAINTS/CLOCKSPRING -
INSTALLATION).
NOTE: Turn the Ignition Switch to the on position
and verify the gear shifter moves. If the shifter does
not move ensure the Ignition Switch is installed
properly.
(2) Column shift vehicles, install a new grommet.
Use multi-purpose lubricant, or equivalent, to aid
installation of the grommet.
NOTE: A new grommet should be used when ever
the rod is disconnected from the lever.
Fig. 5 PRNDL Drive
1 - PRNDL LEVER
2 - THUMB SCREW
3 - CABLE RETAINER
4 - PRNDL CABLE
Fig. 6 Multi-function Switch
1 - STEERING COLUMN ASSY.
2 - MULTI-FUNCTION SWITCH CONNECTOR
3 - TURN SIGNAL SWITCH AND LEVER
Fig. 7 Steering Column Wiring
1 - KEY-IN SWITCH & HALO LIGHT
2 - MULTI-FUNCTION SWITCH
3 - TURN SIGNAL SWITCH & LEVER
4 - IGNITION SWITCH
5 - SPEED CONTROL
19 - 8 COLUMNBR/BE
COLUMN (Continued)