2003 DODGE RAM torque

POWERTRAIN CONTROL MODULE C2 (JTEC) - WHITE 32 WAY
CAV CIRCUIT FUNCTION
1 T54 18VT (5.9L/8.0L) TRANSMISSION TEMPERATURE SENSOR SIGNAL
2 K26 18VT/TN (5.9L/8.0L) FUEL INJECTOR NO. 7 DRIVER
3 K115 18TN (8.0L) FUEL INJECTOR NO.9 DRIVER
4 K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER
5 K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER
6 K38 18GY FUEL INJECTOR NO. 5 DRIVER
7 K97 18BR (4.7L) COIL DRIVER NO. 7
8 K88 18VT/WT (5.9L) GOVERNOR PRESSURE SOLENOID CONTROL
9 K92 18TN/PK (3.7L) COIL DRIVER NO. 2
10 K20 18DG GENERATOR FIELD
11 K54 18OR/BK (5.9L) TORQUE CONVERTER CLUTCH SOLENOID CONTROL
12 K58 18BR/DB FUEL INJECTOR NO. 6 DRIVER
13 K28 18GY/LB (5.9L/8.0L) FUEL INJECTOR NO. 8 DRIVER
14 K116 18WT/DB (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 Y145 18DB/YL CONDENSER FAN RELAY CONTROL
18 - -
19 C18 18DB A/C PRESSURE SIGNAL
20 - -
21 T60 18BR (5.9L/8.0L) 3-4 SHIFT SOLENOID CONTROL
22 - -
23 G60 18GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
24 - -
25 T13 18DB/BK (5.9L8.0L) SPEED SENSOR GROUND
26 - -
27 G7 18WT/OR VEHICLE SPEED SIGNAL
28 T14 18LG/WT (5.9L/8.0L) OUTPUT SPEED SENSOR SIGNAL
29 T25 18LG/RD (5.9L/8.0L) GOVERNOR PRESSURE SENSOR SIGNAL
30 K30 18PK (5.9L/8.0L) TRANSMISSION CONTROL RELAY CONTROL
31 K6 18VT/WT 5 VOLT SUPPLY
32 - -
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 89

POWERTRAIN CONTROL MODULE C3 (JTEC) - GRAY 32 WAY
CAV CIRCUIT FUNCTION
1 C13 18DB/OR A/C CLUTCH RELAY CONTROL
2- -
3 K51 18DB/YL AUTO SHUT DOWN RELAY CONTROL
4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
6- -
7 K73 18YL/BK (3.7L) KNOCK SENSOR NO. 1 SIGNAL
8 K199 18BR/VT OXYGEN SENSOR 1/1 HEATER CONTROL
9 K127 18DB/OR OXYGEN SENSOR DOWNSTREAM RELAY CONTROL
10 K106 18WT/DG LEAK DETECTION PUMP SWITCH SENSE
11 V32 18YL/RD SPEED CONTROL SUPPLY
12 A142 16DG/OR AUTO SHUT DOWN RELAY OUTPUT
13 T6 18OR/WT (5.9L) OVERDRIVE OFF SWITCH SENSE
13 T10 18YL/DG (5.9L DIESEL) TORQUE MANAGEMENT REQUEST SENSE
14 K107 18OR LEAK DETECTION PUMP SOLENOID CONTROL
15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
16 K299 18BR/WT (CALIFORNIA) OXYGEN SENSOR 2/1 HEATER CONTROL
16 K299 18BR/WT (EXCEPT CALIFORNIA) OXYGEN SENSOR 1/2 HEATER CONTROL
17 - -
18 K74 18BR/VT (3.7L) KNOCK SENSOR NO. 2 SIGNAL
19 K31 18BR FUEL PUMP RELAY CONTROL
20 K52 18PK/BK EVAPORATIVE EMISSION SOLENOID CONTROL
21 - -
22 - -
23 - -
24 K29 18WT/PK BRAKE SWITCH SENSE
25 K125 18WT/DB GENERATOR SOURCE
26 G8 18LB/BK FUEL LEVEL SENSOR SIGNAL
27 D21 18PK SCI TRANSMIT
28 - -
29 D20 18LG SCI RECEIVE
30 D25 18VT/BR PCI BUS
31 - -
32 V37 18RD/LG SPEED CONTROL SWITCH SIGNAL
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 91

POWERTRAIN CONTROL MODULE C4 (NGC) - GREEN 38 WAY
CAV CIRCUIT FUNCTION
1 T60 18BR (4.7L) OVERDRIVE SOLENOID CONTROL
2 T159 18DG/WT (4.7L) 4C SOLENOID CONTROL
3 Y207 18RD/WT (5.7L) TPS NO. 1 OUTPUT
4 T140 18VT/LG (4.7L) PRESSURE CONTROL SOLENOID CONTROL
5 Y208 18DB/YL (5.7L) APPS NO. 1 OUTPUT
6 T119 18WT/DB (4.7L) 2C SOLENOID CONTROL
7 T10 18YL/DG (5.7L) TORQUE MANAGEMENT REQUEST SENSE
8 T59 18PK (4.7L) UNDERDRIVE SOLENOID CONTROL
9 Y209 18TN/BK (5.7L) SENSOR GROUND
10 T120 18LG (4.7L) LR SOLENOID CONTROL
11 T118 18YL/DB (4.7L) PRESSURE CONTROL SOLENOID CONTROL
11 Y210 18YL/RD (5.7L EATX) RPM SIGNAL
12 Z13 16BK/RD (4.7L) GROUND
13 Z13 16BK/RD (4.7L) GROUND
14 Z13 16BK/RD (4.7L) GROUND
15 T1 18LG/BK (4.7L) TRS T1 SENSE
16 T3 18VT (4.7L) TRS T3 SENSE
17 T6 18OR/WT (4.7L) OVERDRIVE OFF SWITCH SENSE
18 K30 18PK (4.7L) TRANSMISSION CONTROL RELAY CONTROL
19 T16 16RD (4.7L) TRANSMISSION CONTROL RELAY OUTPUT
20 T48 18DB (4.7L) 4C PRESSURE SWITCH SENSE
21 T29 18GY (4.7L) UNDERDRIVE PRESSURE SWITCH SENSE
22 T9 18OR/BK (4.7L) OVERDRIVE PRESSURE SWITCH SENSE
23 - -
24 - -
25 - -
26 T4 18PK/OR (4.7L) TRS T2 SENSE
27 - -
28 T16 16RD (4.7L) TRANSMISSION CONTROL RELAY OUTPUT
29 T50 18DG (4.7L) LOW/REVERSE PRESSURE SWITCH SENSE
30 T147 18LB (4.7L) 2C PRESSURE SWITCH SENSE
31 T38 18VT/TN (4.7L) LINE PRESSURE SENSOR SIGNAL
32 T14 18LG/WT (4.7L) OUTPUT SPEED SENSOR SIGNAL
33 T52 18RD/BK (4.7L) INPUT SPEED SENSOR SIGNAL
34 T13 18DB/BK (4.7L) SPEED SENSOR GROUND
35 T54 18VT (4.7L) TRANSMISSION TEMPERATURE SENSOR SIGNAL
36 - -
37 T42 18VT/WT (4.7L) TRS T42 SENSE
38 T16 16RD (4.7L) TRANSMISSION CONTROL RELAY OUTPUT
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 93

TRANSMISSION CONTROL MODULE - BLACK 60 WAY
CAV CIRCUIT FUNCTION
1 T1 18LG/BK TRS T1 SENSE
2 T4 18PK/OR TRS T2 SENSE
3 T3 18VT TRS T3 SENSE
4- -
5- -
6 Y210 18YL/RD (5.7L) EATX RPM SIGNAL
6 K24 18GY/BK (3.7L) CRANKSHAFT POSITION SENSOR SIGNAL
7 D15 18WT/DG SCI TRANSMIT (TCM)
8 A41 16YL FUSED IGNITION SWITCH OUTPUT (START)
9 T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE
10 T10 18YL/DG TORQUE MANAGEMENT REQUEST SENSE
11 A51 16RD/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 Y208 18DB/YL (5.7L) APPS NO.1 OUTPUT
12 K22 18OR/DB (3.7L) THROTTLE POSITION SENSOR SIGNAL
13 T13 18DB/BK SPEED SENSOR GROUND
14 T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL
15 K30 19PK TRANSMISSION CONTROL RELAY CONTROL
16 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
17 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
18 T118 18YL/DB PRESSURE CONTROL SOLENOID CONTROL
19 T119 18WT/DB 2C SOLENOID CONTROL
20 T120 18LG LR SOLENOID CONTROL
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 B22 20DG/YL (5.7L) VEHICLE SPEED SIGNAL
28 G7 18WT/OR (3.7L) VEHICLE SPEED SIGNAL
29 T29 18GY UNDERDRIVE PRESSURE SWITCH SENSE
30 T38 18VT/TN LINE PRESSURE SENSOR SIGNAL
31 - -
32 - -
33 - -
34 - -
35 - -
36 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
37 Z13 16BK/RD GROUND
38 T39 18GY/LB 5 VOLT SUPPLY
39 Z13 16BK/RD GROUND
40 T140 18VT/LG MS SOLENOID CONTROL
41 T41 18BK/WT TRS T41 SENSE(C1)
42 T42 18VT/WT TRS T42 SENSE
43 D25 20VT/OR PCI BUS
44 - -
45 Y207 18RD/WT (5.7L) TPS NO.1 OUTPUT
46 D6 18PK/LB SCI TRANSMIT
47 T147 18LB 2C PRESSURE SWITCH SENSE
48 T48 18DB 4C PRESSURE SWITCH SENSE
49 T6 20OR/WT OVERDRIVE OFF SWITCH SENSE
50 T50 18DG LOW/REVERSE PRESSURE SWITCH SENSE
51 Y209 18TN/BK (5.7L) SENSOR GROUND
51 K4 18BK/LB (3.7L) SENSOR GROUND
8W - 80 - 104 8W-80 CONNECTOR PIN-OUTSDR

TRANSMISSION CONTROL MODULE - BLACK 60 WAY
CAV CIRCUIT FUNCTION
52 T52 18RD/BK INPUT SPEED SENSOR SIGNAL
53 Z113 18BK GROUND
54 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
55 T59 18PK UNDERDRIVE SOLENOID CONTROL
56 A61 16DG/BK FUSED B(+)
57 Z13 16BK/RD GROUND
58 - -
59 T159 18DG/WT 4C SOLENOID CONTROL
60 T60 18BR OVERDRIVE SOLENOID CONTROL
TRANSMISSION RANGE SENSOR (5.9L/DIESEL) - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 L10 18BR/LG FUSED IGNITION SWITCH OUTPUT (RUN)
2 Y193 20YL/RD TRANS RANGE SENSOR ELECTRONIC CLUSTER MUX
3- -
4 L1 18VT/BK BACKUP LAMP FEED
5 Y128 20DG/GY TRANS RANGE SENSOR ELECTRONIC CLUSTER 5
VOLT SUPPLY
6 T24 20BR/YL PARK/NEUTRAL POSITION SWITCH SENSE (T41)
TRANSMISSION SOLENOID ASSEMBLY (5.9L/8.0L)-8WAY
CAV CIRCUIT FUNCTION
1 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT
2 K6 18VT/WT 5 VOLT SUPPLY
3 K4 18BK/LB SENSOR GROUND
4 T25 18LG/RD GOVERNOR PRESSURE SENSOR SIGNAL
5 K88 18VT/WT GOVERNOR PRESSURE SOLENOID CONTROL
6 T60 18BR 3-4 SHIFT SOLENOID CONTROL
7 K54 18OR/BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL
8 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 105

(4) Remove the integrated power module retaining
bolt and screw (Fig. 2).
(5) Grasp the integrated power module with two
hands and slide the assembly in the direction shown
(Fig. 3) to free the module from its mounting bracket.
Position the assembly upside down to access the elec-
trical connectors located on the bottom of the unit.
(6) Disconnect the electrical connectors by depress-
ing the locking tab and rotating the connector arm
outboard, until the connector is free from the module
assembly. Be certain to pull the connectors straight
off.
(7) Position the integrated power module on a
bench and remove the four front control module
retaining screws.
(8) Disconnect the front control module by pulling
it straight off the integrated power module.
INSTALLATION
(1) Connect the front control module by pushing it
straight on the integrated power module electrical
receptacle.
(2) Install the four front control module retaining
screws. Torque to 30 in. lbs. +/-5.
NOTE: Integrated power module electrical connec-
tors are color coded to ease location reference (Fig.
4).
(3) Connect the electrical connectors by pushing
straight on and rotating the connector arm inboard,
until the connector is firmly locked in place on the
module assembly.(4) Grasp the integrated power module with two
hands and install the assembly on the battery tray
(Fig. 5).
(5) Install the integrated power module retaining
bolt and screw.
(6) Connect the gray connector on the integrated
power module housing.
(7) Install the B+ terminal cable and nut on the
integrated power module B+ terminal. Snap the
cover in place.
(8) Connect the negative and positive battery
cables.
FRONT CONTROL MODULE
DESCRIPTION
The Front Control Module (FCM) is a micro con-
troller based module located in the left front corner
of the engine compartment. On this model the inte-
grated power module must be positioned aside in
order to access the front control module. The front
control module mates to the power distribution cen-
ter to form the Integrated Power Module (IPM). The
integrated power module connects directly to the bat-
Fig. 3 REMOVING INTEGRATED POWER MODULE
Fig. 4 INTEGRATED POWER MODULE ELECTRICAL
CONNECTIONS
1 - RETAINING LATCH
2 - GRAY CONNECTOR
3 - GREEN CONNECTOR
4 - GREEN CONNECTOR
5 - BLUE CONNECTOR
6 - WHITE CONNECTOR
7 - BLACK CONNECTOR
8 - BLACK CONNECTOR
8W - 97 - 4 8W-97 POWER DISTRIBUTIONDR
INTEGRATED POWER MODULE (Continued)

tery and provides the primary means of circuit pro-
tection and power distribution for all vehicle
electrical systems. The front control module controls
power to some of these vehicle systems electrical and
electromechanical loads based on inputs received
from hard wired switch inputs and data received on
the PCI bus circuit (J1850).
For information on theIntegrated Power Mod-
ule Refer to the Power Distribution Sectionof
the service manual.
OPERATION
As messages are sent over the PCI bus circuit, the
front control module reads these messages and con-
trols power to some of the vehicles electrical systems
by completing the circuit to ground (low side driver)
or completing the circuit to 12 volt power (high side
driver). The following functions areControlledby
the Front Control Module:
²Headlamp Power with Voltage Regulation
²Windshield Wiper ªON/OFFº Relay Actuation
²Windshield Wiper ªHI/LOº Relay Actuation
²Windshield Washer Pump Motor
²Fog Lamp Relay Actuation
²Park Lamp Relay Actuation
²Horn Relay Actuation
The following inputs areReceived/Monitoredby
the Front Control Module:
²B+ Connection Detection²Power Ground
²Ambient Temperature Sensing
²Ignition Switch Run
²Washer Fluid Level Switch
²Windshield Wiper Park Switch
²PCI Bus Circuit
DIAGNOSIS AND TESTING - FRONT CONTROL
MODULE
The front control module is a printed circuit board
based module with a on-board micro-processor. The
front control module interfaces with other electronic
modules in the vehicle via the Programmable Com-
munications Interface (PCI) data bus (J1850). In
order to obtain conclusive testing the Programmable
Communications Interface (PCI) data bus network
and all of the electronic modules that provide inputs
to, or receive outputs from the front control module
must be checked. All PCI (J1850) communication
faults must be resolved prior to further diagnosing
any front control module related issues.
The front control module was designed to be diag-
nosed with an appropriate diagnostic scan tool, such
as the DRB IIIt. The most reliable, efficient, and
accurate means to diagnose the front control module
requires the use of a DRB IIItscan tool and the
proper Body Diagnostic Procedures manual.
Before any testing of the front control module is
attempted, the battery should be fully charged and
all wire harness and ground connections inspected
around the affected areas on the vehicle.
REMOVAL
(1) Disconnect the positive and negative battery
cables from the battery.
(2) Partially remove the integrated power module
from the engine compartment (Refer to 8 - ELECTRI-
CAL/POWER DISTRIBUTION/INTEGRATED
POWER MODULE - REMOVAL).
(3)
Remove the front control module retaining
screws.
(4) Using both hands, pull the front control module
straightfrom the integrated power module assembly
to disconnect the 49-way electrical connector and
remove the front control module from the vehicle.
INSTALLATION
(1) Install the front control module on the inte-
grated power module assembly by pushing the
49-way electrical connector straight in.
(2) Install the front control module retaining
screws. Torque the screws to 7 in. lbs.
(3) Install the integrated power module (Refer to 8
- ELECTRICAL/POWER DISTRIBUTION/INTE-
GRATED POWER MODULE - INSTALLATION).
(4)
Connect the positive and negative battery cables.
Fig. 5 INTEGRATED POWER MODULE MOUNTING
TABS
1 - INTEGRATED POWER MODULE MOUNTING HOLES
2 - BATTERY TRAY ASSEMBLY
3 - FRONT CONTROL MODULE
DR8W-97 POWER DISTRIBUTION 8W - 97 - 5
FRONT CONTROL MODULE (Continued)

ENGINE
TABLE OF CONTENTS
page page
ENGINE - 3.7L............................ 1
ENGINE - 4.7L........................... 87
ENGINE - 5.7L.......................... 176ENGINE - 5.9L.......................... 223
ENGINE 5.9L DIESEL..................... 280
ENGINE 8.0L............................ 351
ENGINE - 3.7L
TABLE OF CONTENTS
page page
ENGINE - 3.7L
DESCRIPTION..........................3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION............4
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE............4
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL..............6
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - LUBRICATION..............7
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE..............8
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE.......8
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS..........9
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS..........9
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........10
REMOVAL.............................10
INSTALLATION.........................11
SPECIFICATIONS
SPECIFICATIONS ± 3.7L ENGINE.........12
TORQUE............................15
SPECIAL TOOLS.......................16
AIR CLEANER ELEMENT
REMOVAL.............................20
INSTALLATION.........................20
CYLINDER HEAD - LEFT
DIAGNOSIS AND TESTING - CYLINDER HEAD
GASKET............................20
REMOVAL.............................21
INSTALLATION.........................23CAMSHAFT(S)
DESCRIPTION.........................24
REMOVAL.............................24
INSTALLATION.........................25
CYLINDER HEAD COVER(S)
DESCRIPTION.........................26
REMOVAL.............................26
INSTALLATION.........................27
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................27
STANDARD PROCEDURE - REFACING......27
REMOVAL.............................28
INSTALLATION.........................29
ROCKER ARM
DESCRIPTION.........................30
REMOVAL.............................30
INSTALLATION.........................30
VALVE GUIDE SEALS
DESCRIPTION.........................31
VALVE SPRINGS
DESCRIPTION.........................31
REMOVAL.............................31
INSTALLATION.........................31
CYLINDER HEAD - RIGHT
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER.....................31
REMOVAL.............................32
INSTALLATION.........................32
CAMSHAFT(S)
DESCRIPTION.........................34
REMOVAL.............................34
INSTALLATION.........................35
CYLINDER HEAD COVER(S)
REMOVAL.............................35
INSTALLATION.........................36
DRENGINE 9 - 1