2003 DODGE RAM Service Repair Manual

battery headrest fuse box belt ad blue cruise control

Page 1721 of 2895

DODGE RAM 2003 Service Repair Manual FUEL INJECTION - GAS
TABLE OF CONTENTS
page page
ACCELERATOR PEDAL
REMOVAL.............................24
INSTALLATION.........................24
ACCELERATOR PEDAL POSITION SENSOR
DESCRIPTION.........

FUEL INJECTION - GAS
TABLE OF CONTENTS
page page
ACCELERATOR PEDAL
REMOVAL.............................24
INSTALLATION.........................24
ACCELERATOR PEDAL POSITION SENSOR
DESCRIPTION.........................25
OPERATION...........................25
REMOVAL.............................25
INSTALLATION.........................25
CRANKSHAFT POSITION SENSOR
DESCRIPTION.........................26
OPERATION...........................26
REMOVAL.............................29
INSTALLATION.........................30
FUEL INJECTOR
DESCRIPTION.........................32
OPERATION
OPERATION - FUEL INJECTOR..........32
OPERATION - PCM OUTPUT............32
REMOVAL.............................32
INSTALLATION.........................33
FUEL PUMP RELAY
DESCRIPTION.........................33
OPERATION...........................33
REMOVAL.............................33
INSTALLATION.........................33
IDLE AIR CONTROL MOTOR
DESCRIPTION.........................33
OPERATION...........................33
REMOVAL.............................34INSTALLATION.........................35
INTAKE AIR TEMPERATURE SENSOR
DESCRIPTION.........................36
OPERATION...........................36
REMOVAL.............................36
INSTALLATION.........................38
MAP SENSOR
DESCRIPTION.........................39
OPERATION...........................39
REMOVAL.............................40
INSTALLATION.........................42
OXYGEN SENSOR
DESCRIPTION.........................43
OPERATION...........................43
REMOVAL.............................44
INSTALLATION.........................45
THROTTLE BODY
DESCRIPTION.........................45
OPERATION...........................45
REMOVAL.............................45
INSTALLATION.........................47
THROTTLE CONTROL CABLE
REMOVAL.............................49
INSTALLATION.........................51
THROTTLE POSITION SENSOR
DESCRIPTION.........................52
OPERATION...........................52
REMOVAL.............................53
INSTALLATION.........................54
ACCELERATOR PEDAL
REMOVAL
The following procedure applies only to vehicles
without the Adjustable Pedal Package (code XAP).
The accelerator pedal is serviced as a complete
assembly including the bracket.
The accelerator cable is connected to the upper
part of the accelerator pedal arm by a plastic
retainer (clip) (Fig. 1). This plastic retainer snaps
into the top of the accelerator pedal arm.
(1) From inside the vehicle, hold up accelerator
pedal. Remove plastic cable retainer (clip) and throt-
tle cable core wire from upper end of accelerator
pedal arm (Fig. 1). Plastic cable retainer (clip) snaps
into pedal arm.(2) Remove 2 accelerator pedal mounting bracket
nuts. Remove accelerator pedal assembly.INSTALLATION
(1) Place accelerator pedal assembly over 2 studs.
(2) Install and tighten 2 mounting nuts. Refer to
Torque Specifications.
(3) Slide throttle cable into opening slot in top of
pedal arm.
(4) Push plastic cable retainer (clip) into accelera-
tor pedal arm opening until it snaps into place.
(5) Before starting engine, operate accelerator
pedal to check for any binding.
14 - 24 FUEL INJECTION - GASDR

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DODGE RAM 2003 Service Repair Manual ACCELERATOR PEDAL
POSITION SENSOR
DESCRIPTION
The Accelerator Pedal Position Sensor (APPS)
assembly is located under the vehicle battery tray. A
cable connects the assembly to the accelerator pedal.
A

ACCELERATOR PEDAL
POSITION SENSOR
DESCRIPTION
The Accelerator Pedal Position Sensor (APPS)
assembly is located under the vehicle battery tray. A
cable connects the assembly to the accelerator pedal.
A plastic cover with a movable door is used to cover
the assembly.
The APPS is used only with the 5.7L V-8 engine.
OPERATION
The Accelerator Pedal Position Sensor (APPS) is a
linear potentiometer. It provides the Powertrain Con-
trol Module (PCM) with a DC voltage signal propor-
tional to the angle, or position of the accelerator
pedal. The APPS signal is translated (along with
other sensors) to place the throttle plate (within the
throttle body) to a pre-determined position.
A mechanical cable is used between the accelerator
pedal and the APPS assembly. Although a cable is
used between the pedal and APPS, a mechanical
cable is not used at the throttle body. Throttle plate
position is electrically determined.
REMOVAL
The APPS is serviced (replaced) as one assembly
including the sensor, plastic housing and cable. The
APPS assembly is located under the vehicle battery
tray (Fig. 2). Access to APPS is gained from over top
of left / front tire.
(1) Disconnect negative battery cable at battery.
(2) Disconnect APPS cable at accelerator pedal.
Refer to Accelerator Pedal Removal / Installation.
(3) Remove wheel house liner at left / front wheel.
Refer to Body.
(4) Gain access to APPS electrical connector by
opening swing-down door (Fig. 3). Disconnect electri-
cal connector.
(5) Remove 3 mounting bolts (Fig. 3).
(6) Remove APPS assembly from battery tray.
(7) If cable is to be separated at APPS, unsnap
cable clip from ball socket (Fig. 4). Release cable from
plastic housing by pressing on small cable release tab
(Fig. 3).
INSTALLATION
(1) Install Accelerator Pedal Position Sensor
(APPS) cable to accelerator pedal. Refer to Accelera-
tor Pedal Removal / Installation.
(2) Connect electrical connector to APPS.
(3) If necessary, connect cable to APPS lever ball
socket (snaps on).
(4) Snap APPS cable cover closed.
Fig. 1 ACCELERATOR PEDAL MOUNTING
1 - ACCELERATOR CABLE
2 - PLASTIC RETAINER (CLIP)
3 - THROTTLE PEDAL ARM
4 - PEDAL / BRACKET ASSEMBLY
5 - CABLE CLIP
Fig. 2 APPS LOCATION
1 - BATTERY TRAY
2 - APPS LOCATION
3 - APPS MOUNTING BOLTS
DRFUEL INJECTION - GAS 14 - 25
ACCELERATOR PEDAL (Continued)

Page 1723 of 2895

DODGE RAM 2003 Service Repair Manual (5) Position APPS assembly to bottom of battery
tray and install 3 bolts. Refer to Torque Specifica-
tions.
(6) Install wheelhouse liner. Refer to Body.
(7) Perform the following procedure:
(a) Connec

(5) Position APPS assembly to bottom of battery
tray and install 3 bolts. Refer to Torque Specifica-
tions.
(6) Install wheelhouse liner. Refer to Body.
(7) Perform the following procedure:
(a) Connect negative battery cable to battery.
(b) Turn ignition switch ON, but do not crank
engine.
(c) Leave ignition switch ON for a minimum of
10 seconds. This will allow PCM to learn electrical
parameters.
(8) If the previous step is not performed, a Diag-
nostic Trouble Code (DTC) will be set.
(9) If necessary, use DRB IIItScan Tool to erase
any Diagnostic Trouble Codes (DTC's) from PCM.
CRANKSHAFT POSITION
SENSOR
DESCRIPTION
3.7L V-6
The Crankshaft Position (CKP) sensor is mounted
into the right rear side of the cylinder block. It is
positioned and bolted into a machined hole.
4.7L V-8
The Crankshaft Position (CKP) sensor is mounted
into the right rear side of the cylinder block. It is
positioned and bolted into a machined hole.
5.7L V-8
The Crankshaft Position (CKP) sensor is mounted
into the right rear side of the cylinder block. It is
positioned and bolted into a machined hole.
5.9L V-8 Gas
The Crankshaft Position (CKP) sensor is located
near the outer edge of the flywheel (starter ringear).
It is bolted to the rear of the engine.
8.0L V-10
The Crankshaft Position (CKP) sensor is located on
the right-lower side of the cylinder block, forward of
the right engine mount, just above the oil pan rail.
OPERATION
3.7L V-6
Engine speed and crankshaft position are provided
through the CKP (Crankshaft Position) sensor. The
sensor generates pulses that are the input sent to the
Powertrain Control Module (PCM). The PCM inter-
prets the sensor input to determine the crankshaft
position. The PCM then uses this position, along with
Fig. 3 APPS REMOVE / INSTALL
1 - BOTTOM OF BATTERY TRAY
2 - ELECTRICAL CONNECTOR
3 - APPS
4 - SWING-DOWN DOOR
5 - CABLE (TO PEDAL)
6 - CABLE RELEASE TAB
Fig. 4 APPS CABLE
1 - APPS LEVER
2 - BALL SOCKET
3 - SWING-DOWN DOOR
4 - CABLE CLIP
5 - CABLE
14 - 26 FUEL INJECTION - GASDR
ACCELERATOR PEDAL POSITION SENSOR (Continued)

Page 1724 of 2895

DODGE RAM 2003 Service Repair Manual other inputs, to determine injector sequence and igni-
tion timing.
The sensor is a hall effect device combined with an
internal magnet. It is also sensitive to steel within a
certain distance from it

other inputs, to determine injector sequence and igni-
tion timing.
The sensor is a hall effect device combined with an
internal magnet. It is also sensitive to steel within a
certain distance from it.
A tonewheel (targetwheel) is bolted to the engine
crankshaft (Fig. 5). This tonewheel has sets of
notches at its outer edge (Fig. 5).
The notches cause a pulse to be generated when
they pass under the sensor. The pulses are the input
to the PCM.
4.7L V-8
Engine speed and crankshaft position are provided
through the crankshaft position sensor. The sensor
generates pulses that are the input sent to the pow-
ertrain control module (PCM). The PCM interprets
the sensor input to determine the crankshaft posi-
tion. The PCM then uses this position, along with
other inputs, to determine injector sequence and igni-
tion timing.
The sensor is a hall effect device combined with an
internal magnet. It is also sensitive to steel within a
certain distance from it.
On the 4.7L V±8 engine, a tonewheel is bolted to
the engine crankshaft (Fig. 6). This tonewheel has
sets of notches at its outer edge (Fig. 6).
The notches cause a pulse to be generated when
they pass under the sensor. The pulses are the input
to the PCM.
5.7L V-8
Engine speed and crankshaft position are provided
through the crankshaft position sensor. The sensor
generates pulses that are the input sent to the pow-
ertrain control module (PCM). The PCM interprets
the sensor input to determine the crankshaft posi-
tion. The PCM then uses this position, along with
other inputs, to determine injector sequence and igni-
tion timing.
The sensor is a hall effect device combined with an
internal magnet. It is also sensitive to steel within a
certain distance from it.
On the 5.7L V±8 engine, a tonewheel is bolted to
the engine crankshaft. This tonewheel has sets of
notches at its outer edge (Fig. 7).
The notches cause a pulse to be generated when
they pass under the sensor. The pulses are the input
to the PCM.
5.9L V-8 Gas
Engine speed and crankshaft position are provided
through the CKP sensor. The sensor generates pulses
that are the input sent to the Powertrain Control
Module (PCM). The PCM interprets the sensor input
to determine the crankshaft position. The PCM then
uses this position, along with other inputs, to deter-
mine injector sequence and ignition timing.
Fig. 5 CKP OPERATION - 3.7L V-6
1 - TONEWHEEL
2 - NOTCHES
3 - CRANKSHAFT POSITION SENSOR
4 - CRANKSHAFT
Fig. 6 CKP SENSOR OPERATION AND TONEWHEEL
- 4.7L V-8
1 - TONEWHEEL
2 - NOTCHES
3 - CRANKSHAFT POSITION SENSOR
4 - CRANKSHAFT
DRFUEL INJECTION - GAS 14 - 27
CRANKSHAFT POSITION SENSOR (Continued)

Page 1725 of 2895

DODGE RAM 2003 Service Repair Manual The sensor is a hall effect device combined with an
internal magnet. It is also sensitive to steel within a
certain distance from it.
On 5.9L V-8 engines, the flywheel/drive plate has 8
single notches

Page 1726 of 2895

DODGE RAM 2003 Service Repair Manual REMOVAL
3.7L V-6
The Crankshaft Position (CKP) sensor is mounted
into the right rear side of the cylinder block (Fig. 10).
It is positioned and bolted into a machined hole.
(1) Raise vehicle.
(2) Disc

Page 1727 of 2895

DODGE RAM 2003 Service Repair Manual 5.9L Gas
The sensor is bolted to the top of the cylinder block
near the rear of right cylinder head (Fig. 13).
(1) Raise vehicle.(2) Disconnect crankshaft position sensor pigtail
harness from main wir

Page 1728 of 2895

DODGE RAM 2003 Service Repair Manual CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) Install mounting bolt and

CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) Install mounting bolt and tighten to 28 N´m
(21 ft. lbs.) torque.
(5) Connect electrical connector to sensor.
(6) Lower vehicle.
4.7L V-8
(1) Clean out machined hole in engine block.
(2) Apply a small amount of engine oil to sensor
o-ring.
(3) Install sensor into engine block with a slight
rocking and twisting action.CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) Install mounting bolt and tighten to 28 N´m
(21 ft. lbs.) torque.
(5) Connect electrical connector to sensor.
(6) Lower vehicle.
5.7L V-8
(1) Clean out machined hole in engine block.
(2) Apply a small amount of engine oil to sensor
o-ring.
(3) Install sensor into engine block with a slight
rocking and twisting action.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) Install mounting bolt and tighten to 28 N´m
(21 ft. lbs.) torque.
(5) Connect electrical connector to sensor.
(6) Lower vehicle.
5.9L V-8 Gas
(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) Lower vehicle.
8.0L V-10
(1) Apply a small amount of engine oil to sensor
o-ring.
(2) Install sensor into cylinder block with a slight
rocking action. Do not twist sensor into position as
damage to o-ring may result.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(3) Install mounting bolt and tighten to 8 N´m (70
in. lbs.) torque.
(4) Connect sensor pigtail harness to main engine
wiring harness
(5) Install new plastic tie strap (Fig. 14) to secure
sensor pigtail harness to side of engine block. Thread
tie strap through casting hole on cylinder block.
Fig. 15 CKP SENSOR R/I ± 8.0L V-10
1 - CRANKSHAFT POSITION SENSOR
2 - MOUNTING BOLT
3 - SENSOR POSITIONED FLUSH TO CYLINDER BLOCK
Fig. 16 SENSOR O-RING ± 8.0L V-10
1 - CRANKSHAFT POSITION SENSOR O-RING
2 - ELECTRICAL CONNECTOR
3 - PIGTAIL HARNESS
DRFUEL INJECTION - GAS 14 - 31
CRANKSHAFT POSITION SENSOR (Continued)

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