2002 DODGE RAM fuel pump

FUEL INJECTOR NO. 10 (8.0L) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K116 18WT FUEL INJECTOR NO. 10 DRIVER
2 A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
FUEL PUMP MODULE (GAS) - LT. GRAY 4 WAY
CAV CIRCUIT FUNCTION
1 Z13 16BK GROUND
2 K4 20BK/LB SENSOR GROUND
3 K226 20DB/WT FUEL LEVEL SENSOR SIGNAL
4 A61 16DG/BK FUEL PUMP RELAY OUTPUT
FUEL TANK MODULE (DIESEL) - LT. GRAY 4 WAY
CAV CIRCUIT FUNCTION
1- -
2 K4 20BK/LB SENSOR GROUND
3 K226 20DB/WT FUEL LEVEL SENSOR SIGNAL
4- -
FUEL TRANSFER PUMP (DIESEL)-2WAY
CAV CIRCUIT FUNCTION
1 K135 18YL/WT TRANSFER PUMP SUPPLY
2 Z11 18BK/WT GROUND
G300 - BLACK 5 WAY
CAV CIRCUIT FUNCTION
1 Z2 18BK/LG GROUND
2 Z2 14BK/LG GROUND
3 Z2 16BK/LG GROUND
4 Z2 16BK/LG GROUND
5 Z2 14BK/LG GROUND
8W - 80 - 46 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

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)

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Right Park/Turn Signal Lamp BK At Lamp N/S
Right Power Mirror BK In Door N/S
Right Rear Fender Lamp BK On Fender 27
Right Rear Speaker BK Bottom of Right B Pillar 23
Right Remote Radio Switch Steering Wheel N/S
Right Speed Control Switch Steering Wheel N/S
Right Tail/Stop Turn Signal
LampBK At Rear Bumper 27
Right Tweeter (Premium) Right A Pillar N/S
Right Visor/Vanity Lamp BK Right A-Pillar N/S
Seat Belt Switch BK Above Left Rear Speaker 23
Seat Heat Interface Module BK Under Seat N/S
Tailgate Lamp On Tailgate 27
Throttle Position Sensor
(Gas)Throttle Body 7, 12
Trailer Tow Connector BK On Trailer Hitch 27
Transmission Range Sensor BK Left side of Transmission N/S
Transmission Solenoid
AssemblyBK Side of Transmission 16
Under Hood Lamp BK Underside of Hood 20
Vehicle Speed Control Servo BK Below Battery 21
Washer Fluid Level Switch BK At Reservoir 21
Water In Fuel Sensor (Diesel) BK Bottom of Fuel Filter/Water Separator 13
Windshield Washer Pump BK Bottom of Washer Fluid Reservior 21
Wiper Motor BK Center Rear Engine Compartment 18
GROUNDS
GROUND
NUMBERLOCATION FIG.
G100 Left Fender Side Shield 21
G101 Left Fender Side Shield 21
G102 Left Fender Side Shield (RWAL Ground) N/S
G103 Near T/O for Wiper Motor 18
G105 Front of Engine (Engine Ground) 7, 8, 12
G107 (Diesel) Left Rear of Engine 13
G113 (Diesel) Primary Battery Engine Ground N/S
G114 Battery Engine Ground N/S
G115 (Diesel) Primary Battery Body Ground N/S
G116 Battery Frame Ground N/S
G117 (Diesel) Auxilary Battery Engine Ground N/S
G118 (Diesel) Primary Frame Ground N/S
G120 (Diesel) Auxilary Battery Body Ground N/S
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONBR/BE
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)

SPLICE
NUMBERLOCATION FIG.
S184 (Diesel) Engine Harnes, in T/O to Engine Control Module N/S
S202 Instrument Panel Harness, Near Overdrive Switch 31
S203 Instrument Panel Harness, Near Overdrive Switch 31
S204 instrument Panel Harness, In T/O to Cup Holder Lamp 31
S207 Instrument Panel Harness, Near Blower Motor 31
S209 Steering Wheel Harness, Near Remote Radio Switch N/S
S210 Steering Wheel Harness, Near Remote Radio Switch N/S
S300 Body Harness, Left Side Instrument Panel 36
S301 Body Harness, Left Side Instrument Panel 36
S302 Body Harness, Left Side Instrument Panel 36
S303 Body Harness, Left Side Instrument Panel 36
S304 Body Harness, Left Side Instrument Panel 36
S305 Body Harness, Right Side Instrument Panel N/S
S306 Body Harness, Left Side Instrument Panel 36
S307 Body Harness, Left Cowl 36
S308 Body Harness, Left Cowl 36
S310 At Left Body Ground N/S
S311 At Left Body Ground N/S
S313 Left Rear Frame Rail 28
S314 Left Rear Frame Rail N/S
S315 Left Rear Frame Rail N/S
S316 Left Rear Frame Rail 28
S317 Left Rear Frame Rail 28
S318 In T/O to Trailer Tow 28
S319 In T/O to Left Rear Lamps 28
S320 In T/O to Trailer Tow 28
S321 In T/O to Left Rear Lamps 28
S322 Overhead Console Harness, At Roof Lamps 26
S323 Overhead Console Harness, At Roof Lamps 26
S324 Overhead Console Harness, At Roof Lamps 26
S325 Overhead Console Harness, At Roof Lamps 26
S326 Overhead Console Harness, At Roof Lamps 26
S327 Power Seat Harness, Near Switch N/S
S328 Power Seat Harness, Near T/O to Body Wiring N/S
S329 Door Harness, Near Left Door Near Grommet N/S
S330 Door Harness, Near Right Door Near Grommet N/S
S331 Chassis Harness, Near T/O to Fuel Pump Module 28
S332 Body Harness, Left Side Instrument Panel 36
S333 Power Seat Harness, Near T/O to Passenger Seat Jumper N/S
S335 Power Seat harness, Near T/O to Body Wiring N/S
S336 Power Seat Harness, Under Passenger Seat N/S
BR/BE8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

ENGINE 5.9L
DESCRIPTION
The 5.9 Liter (360 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve
engine with hydraulic roller tappets. This engine is
designed for unleaded fuel.
The engine lubrication system consists of a rotor
type oil pump and a full flow oil filter.
The cylinders are numbered from front to rear; 1,
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 1) .
The engine serial number is stamped into a
machined pad located on the left, front corner of the
cylinder block. When component part replacement is
necessary, use the engine type and serial number for
reference (Fig. 2) .
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING - Preformance) or (Refer to 9 - ENGINE - DIAG-
NOSIS AND TESTING - Mechanical). Refer to 14 -
FUEL SYSTEM for fuel system diagnosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING)
²Cylinder Combustion Pressure Leakage Test
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
²Cylinder Head Gasket Failure Diagnosis (Refer
to 9 - ENGINE/CYLINDER HEAD - DIAGNOSIS
AND TESTING)
²Intake Manifold Leakage Diagnosis (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
DIAGNOSIS AND TESTING)
²Lash Adjuster (Tappet) Noise Diagnosis (Refer to
9 - ENGINE/ENGINE BLOCK/HYDRAULIC LIFT-
ERS (CAM IN BLOCK) - DIAGNOSIS AND TEST-
ING)
²Engine Oil Leak Inspection (Refer to 9 -
ENGINE/LUBRICATION - DIAGNOSIS AND TEST-
ING)
Fig. 1 Firing Order
Fig. 2 Engine Identification Number
BR/BEENGINE 5.9L 9 - 3

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)