2002 DODGE RAM engine

(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)

(7) Attach the other jumper wire (12V +) to termi-
nal number 86. This will activate the relay. Continu-
ity should now be present between terminals number
87 and 30. Continuity should not be present between
terminals number 87A and 30.
(8) Disconnect jumper wires from relay and 12 Volt
power source.
(9) If continuity or resistance tests did not pass,
replace relay. If tests passed, refer to 8, Wiring Dia-
grams for (fuel system) relay wiring schematics and
for additional circuit information.
REMOVAL
The fuel heater relay is located in the Power Dis-
tribution Center (PDC) (Fig. 22). Refer to label under
PDC cover for relay location.
(1) Remove PDC cover.
(2) Remove relay from PDC.
(3) Check condition of relay terminals and PDC
connector terminals for damage or corrosion. Repair
if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
INSTALLATION
The fuel heater relay is located in the Power Dis-
tribution Center (PDC) (Fig. 22). Refer to label under
PDC cover for relay location.
(1) Install relay to PDC.
(2) Install cover to PDC.
FUEL INJECTION PUMP
DESCRIPTION
DESCRIPTIONÐFUEL PUMP 245 H.P.
Although the fuel injection pump on the 245 horse-
power engine appears similar to other VP 44 injec-
tion pumps, there are internal differences that make
it unique. If pump replacement is necessary, be sure
to verify pump number. The pump number can be
found on the Fuel Injection Pump Data Plate (Fig.
23).
DESCRIPTIONÐFUEL PUMP 235 H.P.
The fuel injection pump is mounted to the rear of
the timing gear housing on the left side of engine
(Fig. 24).
Fig. 22 Power Distribution Center (PDC) Location
1 - CLIP
2 - BATTERY
3 - TRAY
4 - NEGATIVE CABLE
5 - POSITIVE CABLE
6 - CLIP
7 - FENDER INNER SHIELD
8 - POWER DISTRIBUTION CENTER
Fig. 23 Fuel Injection Pump Data Plate Location
1 - PUMP DATA PLATE
BR/BEFUEL DELIVERY - DIESEL 14 - 69
FUEL HEATER RELAY (Continued)

OPERATION
The Bosch VP44 fuel injection pump (Fig. 25) is a
solenoid-valve controlled-radial-piston-distributor
type pump.The injection pump is driven by the engine cam-
shaft. A gear on the end of the pump shaft meshes
with the camshaft gear. The pump is timed to the
engine. The VP44 is controlled by an integral (and
non-serviceable) Fuel Pump Control Module (FPCM)
(Fig. 24). The FPCM can operate the engine as an
engine controller if a Crankshaft Position Sensor
(CKP) signal is not present.
Fuel from the transfer (lift) pump enters the VP44
where it is pressurized and then distributed through
high-pressure lines to the fuel injectors. The VP44 is
cooled by the fuel that flows through it. A greater
quantity of fuel is required for cooling the VP44 than
what is necessary for engine operation. Because of
this, approximately 70 percent of fuel entering the
pump is returned to the fuel tank through the over-
flow valve and fuel return line. Refer to Overflow
Valve Description/Operation for additional informa-
tion.
The VP44 is not self-priming. At least two fuel
injectors must be bled to remove air from the system.
When servicing the fuel system, disconnecting compo-
nents up to the pump will usually not require air
bleeding from the fuel system. However, removal of
the high-pressure lines, removal of the VP44 pump,
or allowing the vehicle to completely run out of fuel,
will require bleeding air from the high-pressure lines
at the fuel injectors.
VP44 timing is matched to engine timing by an off-
set keyway that fits into the pump shaft. This key-
way has a stamped number on it that is matched to
a number on the VP44 pump (each keyway is cali-
brated to each pump).
When removing/installing the VP44, the same
numbered keyway must always be installed.
Also, the arrow on the top of the keyway should
be installed pointed rearward towards the
pump.
Because of electrical control, the injection pump
high and low idle speeds are not adjustable. Also,
adjustment of fuel pump timing is not required and
is not necessary.
DIAGNOSIS AND TESTINGÐFUEL INJECTION
PUMP TIMING
With the Bosch VP44 injection pump, there are no
mechanical adjustments needed for fuel injection tim-
ing. All timing and fuel adjustments are made by the
Engine Control Module (ECM). However, if a Diag-
nostic Trouble Code (DTC) has been stored indicating
an ªengine sync errorº or a ªstatic timing errorº, per-
form the following.
Fig. 24 Fuel Injection Pump Location
1 - FPCM ELECTRICAL CONNECTOR
2 - HIGH-PRESSURE FUEL LINES
3 - FITTINGS
4 - FUEL INJECTION PUMP
5 - FPCM
Fig. 25 Bosch VP44 Fuel Injection Pump
1 - BOSCH VP44 PUMP
14 - 70 FUEL DELIVERY - DIESELBR/BE
FUEL INJECTION PUMP (Continued)

(1) Remove hose clamp and crankcase vent hose at
crankcase breather (Fig. 26). Remove crankcase
breather from gear cover. Breather threads into
cover.
(2) Remove injection pump nut and washer (Fig.
27). Locate keyway behind washer.
(3) Be sure keyway aligning fuel injection pump
shaft to injection pump gear is in proper position and
pump gear has not slipped on pump shaft.
The following steps will require removing timing
gear cover to gain access to timing gears. Refer to
Group 9, Engines for procedures.
(4) Use a T-type puller to separate injection pump
gear from pump shaft.
(5) Be sure keyway has been installed with arrow
pointed torearof pump (Fig. 28).
(6)Pump timing has been calibrated to pump
keyway. Be sure 3±digit number on pump key-
way (Fig. 28) matches 3±digit number on fuel
injection pump data plate. Plate is located on
side of injection pump (Fig. 29). Twenty±one dif-
ferent calibrated keyways/pumps are available.
(7) Verify timing marks on crank, cam and pump
are aligned (Fig. 30).
(8) Perform necessary gear alignment/repairs as
needed.
(9) Install crankcase breather to gear cover. Install
hose clamp and crankcase vent hose to breather (Fig.
26).
(10) After repairs are completed, erase DTC using
DRB Scan Tool.
REMOVAL
CAUTION: Refer to Cleaning Fuel System Parts.
(1) Disconnect both negative battery cables at both
batteries. Cover and isolate ends of cables.
(2) Thoroughly clean fuel lines at cylinder head
and injection pump ends. Thoroughly clean fuel injec-
tion pump and supply/return lines at side of pump.
(3) Disconnect 9±way electrical connector at Fuel
Pump Control Module (FPCM) (Fig. 31).
(4) Remove fuel return line at side of injection
pump by removing overflow valve (Fig. 32). Place rag
beneath overflow valve to catch excess fuel.
(5) Remove fuel supply line at side of injection
pump by removing banjo bolt (Fig. 32). Also remove
same line at top of fuel filter housing (banjo bolt).
(6) Remove all high-pressure fuel lines, intake air
tube, accelerator pedal position sensor, air intake
housing, engine oil dipstick tube, wiring clips, electri-
cal cables at intake heaters and engine lifting
bracket. Refer to High-Pressure Fuel Line Removal/
Installation. All of these items are covered in this
procedure.
(7) Remove hose clamp at crankcase vent hose
(Fig. 33) and remove hose from canister.
(8) Remove (unscrew) canister (Fig. 33) from gear
cover.
Fig. 30 Checking Fuel Injection Pump Gear Timing
1 - PUMP SHAFT
2 - KEYWAY
3 - PUMP GEAR
4 - CAM GEAR
5 - CRANKSHAFT GEAR
Fig. 31 FPCM 9±Way Connector
1 - FPCM ELECTRICAL CONNECTOR
2 - HIGH-PRESSURE FUEL LINES
3 - FITTINGS
4 - FUEL INJECTION PUMP
5 - FPCM
14 - 72 FUEL DELIVERY - DIESELBR/BE
FUEL INJECTION PUMP (Continued)

CAUTION: To prevent pump/gear keyway from fall-
ing into gear housing, engine must be rotated until
keyway is at 12 o'clock position (Fig. 36). If gear
retainer nut, washer or key drops into gear housing,
cover may have to be removed to retrieve them
before engine is started.
(9) Remove nut and washer retaining injection
pump gear to injection pump shaft (Fig. 34).
Fig. 32 Fuel Supply and Return Lines at Pump
1 - FUEL SUPPLY LINE
2 - FUEL RETURN LINE
3 - BANJO BOLT (TEST PORT FITTING)
4 - OVERFLOW VALVE
5 - BANJO FITTING
Fig. 33 Crankcase Vent Hose
1 - HOSE CLAMP
2 - CRANKCASE VENT HOSE
3 - CRANKCASE BREATHER
Fig. 34 Pump Shaft Nut/Washer
1 - WASHER
2 - PUMP NUT
3 - GEAR COVER
Fig. 35 Rotating Engine with Barring Tool
1 - REAR FLANGE
2 - BARRING TOOL
BR/BEFUEL DELIVERY - DIESEL 14 - 73
FUEL INJECTION PUMP (Continued)

(10) The engine can be rotated with a barring tool
such as Snap-On No. SP371, MTE No. 3377371
(Cummins Tool Division), or an equivalent. The open-
ing for barring tool is located in rear flange of engine
on exhaust manifold side (Fig. 35). Remove rubber
access plug covering this opening.
(11) Insert barring tool into flywheel housing open-
ing (Fig. 35).(12) Rotate engine until keyway is at 12 o'clock
position (Fig. 36).
Fig. 36 Placing Keyway at 12 O'clock Position
1 - KEYWAY AT 12 O'CLOCK POSITION
2 - PUMP GEAR
Fig. 37 Separating Injection Pump Gear from Pump
Shaft
1 - T-BAR PULLER
Fig. 38 Rear/Lower Pump Bracket and Mounting
Bolts
1 - FUEL INJECTION PUMP
2 - BOLTS (2)
3 - REAR/LOWER BRACKET
Fig. 39 Injection Pump Mounting Nuts
1 - PUMP MOUNTING NUTS (4)
14 - 74 FUEL DELIVERY - DIESELBR/BE
FUEL INJECTION PUMP (Continued)

(13) Use T-bar type puller (Fig. 37) to separate
injection pump gear from injection pump shaft.
Attach two M8 X 1.24 MM (metric) screws through
puller and into two threaded holes supplied in pump
gear. Pull injection pump gear forward until it loos-
ens from injection pump shaft.Pull on gear only
enough to loosen it from injection pump shaft.
Pulling gear too far may cause damage or
breakage to gear cover.(14) Remove 2 rear/lower pump bracket bolts (Fig.
38).
(15) Remove 4 injection pump-to-gear housing
mounting nuts (Fig. 39).
(16) Remove injection pump from gear housing.
Take care not to nick injection pump shaft on
aluminum gear housing when removing pump.
Also be very careful not to drop pump keyway
(Fig. 41) into gear housing.
CAUTION: Whenever the fuel injection pump is
removed from the engine, the pump drive gear is
laying loose on the camshaft drive gear. Never
attempt to crank or rotate the engine with the pump
removed from the engine. Serious damage will
occur.
INSTALLATION
(1) Inspect pump mounting surfaces at pump and
mounting flange for nicks, cuts or damage. Inspect
o-ring surfaces for nicks, cuts or damage.
(2) Clean injection pump mounting flange (Fig. 40)
at gear housing. Also clean front of injection pump.
(3) Install new rubber o-ring (Fig. 41) at pump
mounting area.
(4) Apply clean engine oilto injection pump
o-ring only.Fig. 40 Cleaning Pump Mounting Flange
1 - PUMP MOUNTING FLANGE
Fig. 41 Keyway, Keyway Arrow and Keyway Number
1 - INJECTION PUMP
2 - DIRECTIONAL ARROW
3 - 3±DIGIT KEYWAY NUMBER
4 - O-RING
Fig. 42 Injection Pump Installation
1 - DOWEL
2 - PUMP
3 - PUMP SHAFT TAPER
4 - INJECTION PUMP GEAR TAPER
BR/BEFUEL DELIVERY - DIESEL 14 - 75
FUEL INJECTION PUMP (Continued)

The machined tapers on both injection pump
shaft and injection pump gear (Fig. 42) must be
absolutely dry, clean and free of any dirt or oil
film. This will ensure proper gear-to-shaft tight-
ening.
(5) Clean pump gear and pump shaft at machined
tapers (Fig. 42) with an evaporative type cleaner
such as brake cleaner.
Keyway Installation:
(6) The pump/gear keyway has an arrow and a
3±digit number stamped at top edge (Fig. 41). Posi-
tion keyway into pump shaft witharrow pointed to
rear of pump.Also be sure 3±digit number stamped
to top of keyway is same as 3±digit number stamped
to injection pump data plate (Fig. 43). If wrong key-
way is installed, a diagnostic trouble code may be
set.
(7) Position pump assembly to mounting flange on
gear cover while aligning injection pump shaft
through back of injection pump gear. When installing
pump, dowel (Fig. 42) on mounting flange must align
to hole in front of pump.(8) After pump is positioned flat to mounting
flange, install four pump mounting nuts and tighten
finger tight only. Do not attempt a final tightening at
this time.Do not attempt to tighten (pull) pump
to gear cover using mounting nuts. Damage to
pump or gear cover may occur. The pump must
be positioned flat to its mounting flange before
attempting to tighten mounting nuts.
(9) To prevent damage or cracking of components,
tighten nuts/bolts in the following sequence:
(a) Install injection pump shaft washer and nut
to pump shaft. Tighten nutfinger tight only.
(b) Install 2 rear/lower pump mounting bolts
finger tight only.
(c) Do preliminary tightening of injection pump
shaft nut to 30 N´m (15±22 ft. lbs.) torque.This is
not the final torque.
(d) Tighten 4 pump mounting nuts to 43 N´m
(32 ft. lbs.) torque.
(e) Tighten 2 rear/lower pump bracket-to-pump
bolts 24 N´m (18 ft. lbs.) torque.
(f) Do final tightening of injection pump shaft
nut to 170 N´m (125 ft. lbs.) torque. Use barring
tool to prevent engine from rotating when tighten-
ing gear.
(10) Install canister (Fig. 33) to gear cover.
(11) Install crankcase vent hose (Fig. 33) to canis-
ter and install hose clamp.
(12) Using new gaskets, install fuel return line
and overflow valve to side of injection pump (Fig. 32).
Tighten overflow valve to 24 N´m (18 ft. lbs.) torque.
(13) Using new gaskets, install fuel supply line to
side of injection pump and top of fuel filter housing
(Fig. 32). Tighten banjo bolts to 24 N´m (18 ft. lbs.)
torque.
(14) Install all high-pressure fuel lines, intake air
tube, accelerator pedal position sensor, air intake
housing, engine oil dipstick tube, wiring clips, electri-
cal cables at intake heaters and engine lifting
bracket. Refer to High-Pressure Fuel Line Removal/
Installation. All of these items are covered in this
procedure.
(15) Connect 9±way electrical connector to Fuel
Pump Control Module (FPCM) (Fig. 31).
(16) Connect both negative battery cables to both
batteries.
(17) Bleed air from fuel system.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE).
(18) Check system for fuel or engine oil leaks.
Fig. 43 Injection Pump Data Plate Location
1 - PUMP DATA PLATE
14 - 76 FUEL DELIVERY - DIESELBR/BE
FUEL INJECTION PUMP (Continued)