2003 DODGE RAM Service Repair Manual

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Page 2849 of 2895

DODGE RAM 2003 Service Repair Manual cover. Loosely hold a piece of stiff paper, such as a
parts tag, over the opening (rubber grommet) at the
valve cover (Fig. 23).(3) The paper should be drawn against the opening
in the valve cover wit

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DODGE RAM 2003 Service Repair Manual (5) Replace the PCV valve and retest the system if
it does not operate as described in the preceding
tests.Do not attempt to clean the old PCV valve.
(6) If the paper is not held against the opening i

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DODGE RAM 2003 Service Repair Manual tabs, valve must be pointed downward for
removal. Do not force valve from oil filler tube.
(3) After valve is removed, check condition of valve
o-ring (Fig. 25).
5.7L V-8
The PCV valve is mounted into

tabs, valve must be pointed downward for
removal. Do not force valve from oil filler tube.
(3) After valve is removed, check condition of valve
o-ring (Fig. 25).
5.7L V-8
The PCV valve is mounted into the top of the
intake manifold, located to the right / rear of the
throttle body (Fig. 12). The PCV valve is sealed to
the intake manifold with 2 o-rings (Fig. 13).
(1) Remove PCV valve by rotating counter-clock-
wise 90 degrees until locating tabs have been freed.
After tabs have cleared, pull valve straight up from
intake manifold.
(2) After valve is removed, check condition of 2
valve o-rings.
INSTALLATION
3.7L V6 / 4.7L V-8
The PCV valve is located on the oil filler tube. Two
locating tabs are located on the side of the valve.
These 2 tabs fit into a cam lock in the oil filler tube.
An o-ring seals the valve to the filler tube.
(1) Return PCV valve back to oil filler tube by
placing valve locating tabs into cam lock. Press PCV
valve in and rotate valve upward. A slight click will
be felt when tabs have engaged cam lock. Valve
should be pointed towards rear of vehicle.
(2) Connect PCV line/hose and rubber hose to PCV
valve.
5.7L V-8
(1) Clean out intake manifold opening.
(2) Check condition of 2 o-rings on PCV valve.
(3) Apply engine oil to 2 o-rings.
(4) Place PCV valve into intake manifold and
rotate 90 degrees clockwise for installation.
VACUUM LINES
DESCRIPTION
A vacuum schematic for emission related items can
be found on the vehicles VECI label. Refer to Vehicle
Emission Control Information (VECI) Label for label
location.
VAPOR CANISTER
DESCRIPTION
Two, maintenance free, EVAP canisters are used.
Both canisters are mounted into a two-piece support
bracket located near the front of the fuel tank (Fig.
26).
OPERATION
Two, maintenance free, EVAP canisters are
used.The EVAP canisters are filled with granules of
an activated carbon mixture. Fuel vapors entering
the EVAP canisters are absorbed by the charcoal
granules.
Fuel tank pressure vents into the EVAP canisters.
Fuel vapors are temporarily held in the canisters
until they can be drawn into the intake manifold.
The duty cycle EVAP canister purge solenoid allows
the EVAP canisters to be purged at predetermined
times and at certain engine operating conditions.
REMOVAL
Two, maintenance free, EVAP canisters are used.
Both canisters are mounted into a two-piece support
bracket located near the front of the fuel tank (Fig.
26).
(1) Raise and support vehicle.
(2) Remove fuel tubes/lines at each EVAP canister.
Note location of tubes/lines before removal for easier
installation.
(3) Remove lower support bracket (Fig. 27).
(4) Remove mounting nuts at top of each canister
(Fig. 27).
Fig. 26 LOCATION, EVAP CANISTERS
1 - LDP
2 - LDP MOUNTING BOLT
3 - ELEC. CONNEC.
4 - FILTER MOUNTING BOLT
5 - LDP FILTER
6 - CONNECTING HOSE
7 - EVAP CANISTER MOUNTING BRACKET
8 - EVAP CANISTERS (2)
25 - 22 EVAPORATIVE EMISSIONSDR
PCV VALVE (Continued)

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DODGE RAM 2003 Service Repair Manual (5) Remove each canister from upper support
bracket.
INSTALLATION
(1) Place each canister into upper support bracket
and install nuts. Refer to Torque Specifications.
(2) Install lower support bracket

(5) Remove each canister from upper support
bracket.
INSTALLATION
(1) Place each canister into upper support bracket
and install nuts. Refer to Torque Specifications.
(2) Install lower support bracket. Refer to Torque
Specifications.
(3) Carefully install vapor/vacuum lines.The
vapor/vacuum lines and hoses must be firmly
connected. Also check the vapor/vacuum lines
at the LDP, LDP filter and EVAP canister purge
solenoid for damage or leaks. If a leak is
present, a Diagnostic Trouble Code (DTC) may
be set.
NATURAL VAC LEAK
DETECTION ASSY
DESCRIPTION
Vehicles equipped with NGC engine control mod-
ules use an NVLD pump and system.Vehicles
equipped with JTEC engine control modules use an
LDP (leak detection pump). Refer to Leak Detection
Pump (LDP) for additional information.The NVLD pump is located in the same area as the
leak detection pump. Refer to NVLD Removal /
Installation for additional information.
OPERATION
Vehicles equipped with NGC engine control mod-
ules use an NVLD pump and system.Vehicles
equipped with JTEC engine control modules use a
leak detection pump. Refer to Leak Detection Pump
(LDP) for additional information.
The Natural Vacuum Leak Detection (NVLD) sys-
tem is the next generation evaporative leak detection
system that will first be used on vehicles equipped
with the Next Generation Controller (NGC). This
new system replaces the leak detection pump as the
method of evaporative system leak detection. This is
to detect a leak equivalent to a 0.0209(0.5 mm) hole.
This system has the capability to detect holes of this
size very dependably.
The basic leak detection theory employed with
NVLD is the9Gas Law9. This is to say that the pres-
sure in a sealed vessel will change if the temperature
of the gas in the vessel changes. The vessel will only
see this effect if it is indeed sealed. Even small leaks
will allow the pressure in the vessel to come to equi-
librium with the ambient pressure. In addition to the
Fig. 27 EVAP CANISTERS - REMOVAL / INSTALLATION
1 - CANISTER MOUNTING NUTS
2 - CONNECTING HOSE
3 - UPPER SUPPORT BRACKET4 - LOWER SUPPORT BRACKET
5 - OUTER CANISTER
6 - INNER CANISTER
DREVAPORATIVE EMISSIONS 25 - 23
VAPOR CANISTER (Continued)

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DODGE RAM 2003 Service Repair Manual detection of very small leaks, this system has the
capability of detecting medium as well as large evap-
orative system leaks.
A vent valve seals the canister vent during engine
off conditions. If the

detection of very small leaks, this system has the
capability of detecting medium as well as large evap-
orative system leaks.
A vent valve seals the canister vent during engine
off conditions. If the vapor system has a leak of less
than the failure threshold, the evaporative system
will be pulled into a vacuum, either due to the cool
down from operating temperature or diurnal ambient
temperature cycling. The diurnal effect is considered
one of the primary contributors to the leak determi-
nation by this diagnostic. When the vacuum in the
system exceeds about 19H2O (0.25 KPA), a vacuum
switch closes. The switch closure sends a signal to
the NGC. The NGC, via appropriate logic strategies,
utilizes the switch signal, or lack thereof, to make a
determination of whether a leak is present.
The NVLD device is designed with a normally open
vacuum switch, a normally closed solenoid, and a
seal, which is actuated by both the solenoid and a
diaphragm. The NVLD is located on the atmospheric
vent side of the canister. The NVLD assembly may
be mounted on top of the canister outlet, or in-line
between the canister and atmospheric vent filter. The
normally open vacuum switch will close with about 19
H2O (0.25 KPA) vacuum in the evaporative system.
The diaphragm actuates the switch. This is above the
opening point of the fuel inlet check valve in the fill
tube so cap off leaks can be detected. Submerged fill
systems must have recirculation lines that do not
have the in-line normally closed check valve that pro-
tects the system from failed nozzle liquid ingestion,
in order to detect cap off conditions.
The normally closed valve in the NVLD is intended
to maintain the seal on the evaporative system dur-
ing the engine off condition. If vacuum in the evapo-
rative system exceeds 39to 69H2O (0.75 to 1.5 KPA),
the valve will be pulled off the seat, opening the seal.
This will protect the system from excessive vacuum
as well as allowing sufficient purge flow in the event
that the solenoid was to become inoperative.
The solenoid actuates the valve to unseal the can-
ister vent while the engine is running. It also will be
used to close the vent during the medium and large
leak tests and during the purge flow check. This sole-
noid requires initial 1.5 amps of current to pull the
valve open but after 100 ms. will be duty cycled down
to an average of about 150 mA for the remainder of
the drive cycle.
Another feature in the device is a diaphragm that
will open the seal in the NVLD with pressure in the
evaporative system. The device will9blow off9at
about 0.59H2O (0.12 KPA) pressure to permit the
venting of vapors during refueling. An added benefit
to this is that it will also allow the tank to9breathe9
during increasing temperatures, thus limiting the
pressure in the tank to this low level. This is benefi-cial because the induced vacuum during a subse-
quent declining temperature will achieve the switch
closed (pass threshold) sooner than if the tank had to
decay from a built up pressure.
The device itself has 3 wires: Switch sense, sole-
noid driver and ground. It also includes a resistor to
protect the switch from a short to battery or a short
to ground. The NGC utilizes a high-side driver to
energize and duty-cycle the solenoid.
REMOVAL
The NVLD pump and filter are attached to the
front of the EVAP canister mounting bracket (Fig.
28). This is located near the front of the fuel tank.
The pump and filter are replaced (serviced) as one
unit.
(1) Raise and support vehicle.
(2) Carefully remove pump hose clamp and hose at
filter.
(3) Carefully remove other vapor/vacuum hose at
pump.
(4) Disconnect 3±way electrical connector at pump.
(5) The NVLD pump snaps onto the EVAP canister
mounting bracket. Press on release tab (Fig. 29)
while sliding pump from bracket.
INSTALLATION
(1) Install NVLD pump to EVAP canister mount-
ing bracket (snaps on).
Fig. 28 NVLD PUMP LOCATION
1 - EVAP CANISTER MOUNTING BRACKET
2 - NVLD PUMP
3 - FILTER
25 - 24 EVAPORATIVE EMISSIONSDR
NATURAL VAC LEAK DETECTION ASSY (Continued)

Page 2854 of 2895

DODGE RAM 2003 Service Repair Manual (2) Install NVLD filter and bolt to EVAP canister
mounting bracket. Refer to Torque Specifications.(3) Carefully install vapor/vacuum lines to NVLD
pump, and install hose to filter.The vapor/vacuum
li

Page 2855 of 2895

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DODGE RAM 2003 Service Repair Manual ABS - DESCRIPTION, BRAKES...........5-39
ABS - OPERATION, BRAKES.............5-39
ABS BRAKE BLEEDING - STANDARD
PROCEDURE.........................5-40
ABS INDICATOR - DESCRIPTION.........8J-17
ABS IND

ABS - DESCRIPTION, BRAKES...........5-39
ABS - OPERATION, BRAKES.............5-39
ABS BRAKE BLEEDING - STANDARD
PROCEDURE.........................5-40
ABS INDICATOR - DESCRIPTION.........8J-17
ABS INDICATOR - OPERATION..........8J-17
A/C APPLICATION TABLE,
SPECIFICATIONS......................24-7
A/C COMPRESSOR CLUTCH -
DESCRIPTION........................24-9
A/C COMPRESSOR CLUTCH -
INSPECTION........................24-12
A/C COMPRESSOR CLUTCH -
INSTALLATION.......................24-12
A/C COMPRESSOR CLUTCH -
OPERATION..........................24-9
A/C COMPRESSOR CLUTCH - REMOVAL . . 24-10
A/C COMPRESSOR CLUTCH BREAK-IN -
STANDARD PROCEDURE...............24-10
A/C COMPRESSOR CLUTCH COIL -
DIAGNOSIS AND TESTING.............24-10
A/C COMPRESSOR CLUTCH RELAY -
DESCRIPTION.......................24-13
A/C COMPRESSOR CLUTCH RELAY -
INSTALLATION.......................24-14
A/C COMPRESSOR CLUTCH RELAY -
OPERATION.........................24-13
A/C COMPRESSOR CLUTCH RELAY -
REMOVAL..........................24-14
A/C COMPRESSOR NOISE - DIAGNOSIS
AND TESTING.......................24-36
A/C CONDENSER - DESCRIPTION.........24-39
A/C CONDENSER - OPERATION..........24-39
A/C EVAPORATOR - DESCRIPTION.......24-47
A/C EVAPORATOR - INSTALLATION......24-47
A/C EVAPORATOR - OPERATION.........24-47
A/C EVAPORATOR - REMOVAL..........24-47
A/C HEATER CONTROL - DESCRIPTION . . . 24-14
A/C HEATER CONTROL - INSTALLATION . . . 24-15
A/C HEATER CONTROL - REMOVAL......24-14
A/C ORIFICE TUBE - DESCRIPTION.......24-48
A/C ORIFICE TUBE - INSTALLATION......24-49
A/C ORIFICE TUBE - OPERATION........24-48
A/C ORIFICE TUBE - REMOVAL..........24-49
A/C PERFORMANCE - DIAGNOSIS AND
TESTING............................24-2
A/C PRESSURE TRANSDUCER -
DESCRIPTION.......................24-15
A/C PRESSURE TRANSDUCER -
DIAGNOSIS AND TESTING.............24-15
A/C PRESSURE TRANSDUCER -
INSTALLATION.......................24-16
A/C PRESSURE TRANSDUCER -
OPERATION.........................24-15
A/C PRESSURE TRANSDUCER -
REMOVAL..........................24-16
ACCELERATOR PEDAL - INSTALLATION . . . 14-24
ACCELERATOR PEDAL - REMOVAL.......14-24
ACCELERATOR PEDAL POSITION
SENSOR - DESCRIPTION...............14-25
ACCELERATOR PEDAL POSITION
SENSOR - INSTALLATION..............14-25
ACCELERATOR PEDAL POSITION
SENSOR - OPERATION................14-25
ACCELERATOR PEDAL POSITION
SENSOR - REMOVAL..................14-25
ACCESSORY DRIVE BELT - DIAGNOSIS
AND TESTING................7-25,7-28,7-31
ACCUMULATOR - DESCRIPTION.........24-49
ACCUMULATOR - DESCRIPTION
. . 21-191,21-372
ACCUMULATOR - INSPECTION
. . . 21-192,21-373
ACCUMULATOR - INSTALLATION
........24-50
ACCUMULATOR - OPERATION
..........24-49
ACCUMULATOR - OPERATION
....21-192,21-373
ACCUMULATOR - REMOVAL
............24-49
ACM COVER - INSTALLATION
............8O-9
ACM COVER - REMOVAL
...............8O-9
ACTUATION TEST MODE - DESCRIPTION,
CIRCUIT
.............................25-1
ACTUATOR - DESCRIPTION, BLEND
DOOR
.............................24-16
ACTUATOR - DESCRIPTION, FUEL
CONTROL
..........................14-85
ACTUATOR - DESCRIPTION, MODE
DOOR
.............................24-20
ACTUATOR - DESCRIPTION,
RECIRCULATION DOOR
................24-22ACTUATOR - INSTALLATION, BLEND
DOOR.............................24-17
ACTUATOR - INSTALLATION, FLOOR -
DEFROST DOOR.....................24-20
ACTUATOR - INSTALLATION, FUEL
CONTROL..........................14-85
ACTUATOR - INSTALLATION, INSIDE
HANDLE.......................23-22,23-32
ACTUATOR - INSTALLATION, MODE
DOOR.............................24-22
ACTUATOR - INSTALLATION,
RECIRCULATION DOOR................24-23
ACTUATOR - OPERATION, BLEND DOOR . . 24-16
ACTUATOR - OPERATION, FUEL
CONTROL..........................14-85
ACTUATOR - OPERATION, MODE DOOR . . . 24-21
ACTUATOR - OPERATION,
RECIRCULATION DOOR................24-22
ACTUATOR - REMOVAL, BLEND DOOR....24-17
ACTUATOR - REMOVAL, FLOOR -
DEFROST DOOR.....................24-19
ACTUATOR - REMOVAL, FUEL CONTROL . . 14-85
ACTUATOR - REMOVAL, INSIDE HANDLE . 23-22,
23-31
ACTUATOR - REMOVAL, MODE DOOR....24-21
ACTUATOR - REMOVAL, RECIRCULATION
DOOR.............................24-22
ADAPTER HOUSING SEAL -
INSTALLATION...........21-127,21-539,21-83
ADAPTER HOUSING SEAL - REMOVAL . . 21-127,
21-539,21-83
ADAPTER MOUNT - INSTALLATION, DISC
BRAKE CALIPER......................5-17
ADDING ADDITIONAL COOLANT -
STANDARD PROCEDURE................7-19
ADDITIONAL COOLANT - STANDARD
PROCEDURE, ADDING..................7-19
ADHESIVE LOCATIONS -
SPECIFICATIONS, STRUCTURAL........23-113
ADJUSTABLE PEDAL MOTOR -
DESCRIPTION........................5-24
ADJUSTABLE PEDAL MOTOR -
INSTALLATION........................5-24
ADJUSTABLE PEDAL MOTOR - REMOVAL . . 5-24
ADJUSTABLE PEDAL SWITCH -
INSTALLATION.........................5-6
ADJUSTABLE PEDAL SWITCH -
REMOVAL............................5-6
ADJUSTER - DIAGNOSIS AND TESTING,
HYDRAULIC LASH................9-124,9-31
ADJUSTER - INSTALLATION, SEAT BELT
TURNING LOOP.....................8O-50
ADJUSTER - REMOVAL, SEAT BELT
TURNING LOOP.....................8O-50
ADJUSTER ASSEMBLY - DESCRIPTION,
ROCKER ARM.......................9-124
ADJUSTER ASSEMBLY - INSTALLATION,
ROCKER ARM..................9-124,9-249
ADJUSTER ASSEMBLY - REMOVAL,
ROCKER ARM..................9-124,9-249
ADJUSTER ASSY - CLEANING, ROCKER
ARM
..............................9-310
ADJUSTER ASSY - DESCRIPTION,
ROCKER ARM
.......................9-310
ADJUSTER ASSY - INSPECTION,
ROCKER ARM
.......................9-311
ADJUSTER ASSY - INSTALLATION,
ROCKER ARM
.............9-198,9-312,9-379
ADJUSTER ASSY - REMOVAL, ROCKER
ARM
....................9-198,9-310,9-379
ADJUSTING TOOL - ADJUSTMENT, WITH
. . . 5-36
AFTER A SUPPLEMENTAL RESTRAINT
DEPLOYMENT - STANDARD
PROCEDURE, SERVICE
.................8O-7
AIR CHECKING TRANSMISSION CLUTCH
OPERATION - DIAGNOSIS AND
TESTING
..........................21-494
AIR CLEANER ELEMENT - INSTALLATION
. 9-105,
9-20,9-242,9-298,9-370
AIR CLEANER ELEMENT - REMOVAL
. 9-105,9-20,
9-242,9-297,9-370
AIR CONDITIONER - DESCRIPTION,
HEATER
.............................24-1
AIR CONDITIONER - OPERATION,
HEATER
.............................24-1
AIR CONDITIONING - INSTALLATION,
WATER PUMP BYPASS HOSE WITH
.......7-70AIR CONDITIONING - INSTALLATION,
WATER PUMP BYPASS HOSE
WITHOUT............................7-70
AIR CONDITIONING - REMOVAL, WATER
PUMP BYPASS HOSE WITH.............7-68
AIR CONDITIONING - REMOVAL, WATER
PUMP BYPASS HOSE WITHOUT..........7-69
AIR CONTROL MOTOR - DESCRIPTION,
IDLE...............................14-33
AIR CONTROL MOTOR - INSTALLATION,
IDLE...............................14-35
AIR CONTROL MOTOR - OPERATION,
IDLE...............................14-33
AIR CONTROL MOTOR - REMOVAL, IDLE . . 14-34
AIR COOLER AND PLUMBING -
CLEANING, CHARGE..................11-16
AIR COOLER AND PLUMBING -
DESCRIPTION, CHARGE...............11-15
AIR COOLER AND PLUMBING -
INSPECTION, CHARGE.................11-16
AIR COOLER AND PLUMBING -
INSTALLATION, CHARGE...............11-16
AIR COOLER AND PLUMBING -
OPERATION, CHARGE.................11-15
AIR COOLER AND PLUMBING -
REMOVAL, CHARGE..................11-15
AIR COOLER SYSTEM - LEAKS -
DIAGNOSIS AND TESTING, CHARGE......11-15
AIR DAM - INSTALLATION, FRONT........13-2
AIR DAM - REMOVAL, FRONT...........13-2
AIR HEATER - DESCRIPTION, INTAKE.....14-91
AIR HEATER - INSTALLATION, INTAKE....14-91
AIR HEATER - OPERATION, INTAKE......14-91
AIR HEATER - REMOVAL, INTAKE........14-91
AIR HEATER RELAY - DESCRIPTION,
INTAKE ............................14-92
AIR HEATER RELAY - INSTALLATION,
INTAKE ............................14-93
AIR HEATER RELAY - OPERATION,
INTAKE ............................14-92
AIR HEATER RELAY - REMOVAL, INTAKE . . 14-93
AIR INTAKE SYSTEM - INSTALLATION....9-194
AIR INTAKE SYSTEM - REMOVAL........9-194
AIR TEMPERATURE SENSOR -
DESCRIPTION, INTAKE................14-36
AIR TEMPERATURE SENSOR -
INSTALLATION, INTAKE................14-38
AIR TEMPERATURE SENSOR -
OPERATION, INTAKE..................14-36
AIR TEMPERATURE SENSOR -
REMOVAL, INTAKE...................14-36
AIR TEMPERATURE SENSOR/MAP
SENSOR - DESCRIPTION, INTAKE........14-93
AIR TEMPERATURE SENSOR/MAP
SENSOR - INSTALLATION, INTAKE.......14-94
AIR TEMPERATURE SENSOR/MAP
SENSOR - OPERATION, INTAKE.........14-93
AIR TEMPERATURE SENSOR/MAP
SENSOR - REMOVAL, INTAKE...........14-93
AIR TEMPERATURE SENSOR/PRESSURE
SENSOR - DESCRIPTION, INLET.........14-90
AIR TEMPERATURE SENSOR/PRESSURE
SENSOR - INSTALLATION, INLET........14-90
AIR TEMPERATURE SENSOR/PRESSURE
SENSOR - OPERATION, INLET..........14-90
AIR TEMPERATURE SENSOR/PRESSURE
SENSOR - REMOVAL, INLET............14-90
AIR TESTING TRANSMISSION CLUTCH
AND BAND OPERATION - DIAGNOSIS
AND TESTING................21-143,21-324
AIR TO OIL COOLER - INSTALLATION.....7-75
AIR TO OIL COOLER - REMOVAL.........7-74
AIRBAG - DESCRIPTION, DRIVER........8O-22
AIRBAG - DESCRIPTION, PASSENGER....8O-34
AIRBAG - DESCRIPTION, SIDE CURTAIN . . 8O-51
AIRBAG - INSTALLATION, DRIVER.......8O-24
AIRBAG - INSTALLATION, PASSENGER . . . 8O-37
AIRBAG - INSTALLATION, SIDE CURTAIN . . 8O-53
AIRBAG - OPERATION, DRIVER.........8O-23
AIRBAG - OPERATION, PASSENGER......8O-35
AIRBAG - OPERATION, SIDE CURTAIN....8O-51
AIRBAG - REMOVAL, DRIVER
...........8O-23
AIRBAG - REMOVAL, PASSENGER
.......8O-35
AIRBAG - REMOVAL, SIDE CURTAIN
.....8O-52
AIRBAG CONTROL MODULE -
DESCRIPTION
.......................8O-10
AIRBAG CONTROL MODULE -
DESCRIPTION, SIDE IMPACT
...........8O-53
DRINDEX 1
Description Group-Page Description Group-Page Description Group-Page

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