2003 DODGE RAM service

STANDARD PROCEDURE - FUEL SYSTEM
PRIMING
A certain amount of air becomes trapped in the
fuel system when fuel system components on the
supply and/or high-pressure side are serviced or
replaced. Fuel system priming is accomplished using
the electric fuel transfer (lift) pump.
Servicing or replacing fuel system components usu-
ally will not require fuel system priming.
The fuel transfer (lift) pump is self-priming: When
the key is first turned on (without cranking engine),
the pump operates for approximately 2 seconds and
then shuts off. The pump will also operate for up to25 seconds after the starter is quickly engaged, and
then disengaged without allowing the engine to start.
The pump shuts off immediately if the key is on and
the engine stops running.
(1) Turn key to CRANK position and quickly
release key to ON position before engine starts. This
will operate fuel transfer pump for approximately 25
seconds.
(2) If the engine does not start after 25 seconds,
turn key OFF. Repeat previous step until engine
starts.
(3) Fuel system priming is now completed.
(4) Attempt to start engine. If engine will not
start, proceed to following steps.When engine does
start, it may run erratically and be noisy for a
few minutes. This is a normal condition.
CAUTION: Do not engage the starter motor for more
than 30 seconds at a time. Allow two minutes
between cranking intervals.
(5) Perform previous fuel priming procedure steps
using fuel transfer pump. Be sure fuel is present at
fuel tank.
(6) Crank the engine for 30 seconds at a time to
allow fuel system to prime.
WARNING: THE FUEL INJECTION PUMP SUPPLIES
EXTREMELY HIGH FUEL PRESSURE TO EACH INDI-
VIDUAL INJECTOR THROUGH THE HIGH-PRES-
SURE LINES. FUEL UNDER THIS AMOUNT OF
PRESSURE CAN PENETRATE THE SKIN AND
CAUSE PERSONAL INJURY. WEAR SAFETY GOG-
GLES AND ADEQUATE PROTECTIVE CLOTHING.
DO NOT LOOSEN FUEL FITTINGS WHILE ENGINE
IS RUNNING.
WARNING: ENGINE MAY START WHILE CRANKING
STARTER MOTOR.
Fig. 2 FUEL INJECTORS
1 - SOLENOID CONNECTIONS
2 - ROCKER HOUSING
3 - FUEL INJECTOR
4 - PASSTHROUGH CONNECTOR
DRFUEL DELIVERY - DIESEL 14 - 59
FUEL DELIVERY - DIESEL (Continued)

(4) Be sure pump is positioned flat to fuel filter
housing. Install mounting bolts and evenly tighten to
7 N´m (61 in. lbs.).
(5) Connect fuel line extension at fuel supply line.
(6) Connect electrical connector to pump.
(7)Prime System:Cycle key to actuate transfer
pump or use DRB II Scan Tool to actuate transfer
pump. Check for leaks.
(8) Operate engine and check for fuel leaks.
CASCADE OVERFLOW VALVE
DESCRIPTION
The cascade overflow valve is located on the top/
rear side of the fuel injection pump (Fig. 27).
OPERATION
When the fuel control actuator (FCA) is opened,
the maximum amount of fuel is being delivered to
the fuel injection pump. Any fuel that does not enter
the injection pump is directed to the cascade overflow
valve. The cascade valve regulates how much excess
fuel is used for lubrication of the injection pump, and
is also used to route excess fuel through the drain
circuit and back into the fuel tank.
REMOVAL
REMOVAL/INSTALLATION
The cascade overflow valve is not serviced sepa-
rately.
WATER IN FUEL SENSOR
DESCRIPTION
The Water-In-Fuel (WIF) sensor is located on the
side of the fuel filter/water separator canister (Fig.
28), or (Fig. 29).
Fig. 27 OVERFLOW VALVE
1 - BANJO BOLTS
2 - PUMP MOUNTING NUTS (3)
3 - FUEL INJECTION PUMP
4 - CASCADE OVERFLOW VALVE
Fig. 28 FILTER HOUSING (EARLY)
1 - FILTER HOUSING
2 - FUEL HEATER AND THERMOSTAT
3 - FUEL HEATER MOUNTING SCREWS
4 - FUEL HEATER ELEC. CONNECTOR
5 - DRAIN VALVE
6 - DRAIN VALVE MOUNTING SCREWS
7 - DRAIN HOSE
8 - WIF SENSOR
9 - WIF SENSOR ELEC. CONNECTOR
DRFUEL DELIVERY - DIESEL 14 - 77
FUEL TRANSFER PUMP (Continued)

FUEL INJECTION - DIESEL
TABLE OF CONTENTS
page page
ACCELERATOR PEDAL POSITION SENSOR
DESCRIPTION
DESCRIPTION (EARLY)................79
DESCRIPTION (LATE)..................79
OPERATION...........................79
REMOVAL.............................79
INSTALLATION.........................82
CAMSHAFT POSITION SENSOR
DESCRIPTION.........................82
OPERATION...........................82
REMOVAL.............................83
INSTALLATION.........................83
CRANKSHAFT POSITION SENSOR
DESCRIPTION.........................83
OPERATION...........................83
REMOVAL.............................84
INSTALLATION.........................84
FUEL CONTROL ACTUATOR
DESCRIPTION.........................85
OPERATION...........................85
REMOVAL.............................85
INSTALLATION.........................85
FUEL INJECTOR
DESCRIPTION.........................85
OPERATION...........................86
REMOVAL.............................87
INSTALLATION.........................87
FUEL INJECTOR RAIL
DESCRIPTION.........................89
OPERATION...........................89REMOVAL.............................89
INSTALLATION.........................90
INLET AIR TEMPERATURE SENSOR/
PRESSURE SENSOR
DESCRIPTION.........................90
OPERATION...........................90
REMOVAL.............................90
INSTALLATION.........................90
INTAKE AIR HEATER
DESCRIPTION.........................91
OPERATION...........................91
REMOVAL.............................91
INSTALLATION.........................91
INTAKE AIR HEATER RELAY
DESCRIPTION.........................92
OPERATION...........................92
REMOVAL.............................93
INSTALLATION.........................93
INTAKE AIR TEMPERATURE SENSOR/MAP
SENSOR
DESCRIPTION.........................93
OPERATION...........................93
REMOVAL.............................93
INSTALLATION.........................94
MAP SENSOR
DESCRIPTION.........................94
THROTTLE CONTROL CABLE
REMOVAL.............................94
INSTALLATION.........................96
ACCELERATOR PEDAL
POSITION SENSOR
DESCRIPTION
DESCRIPTION (EARLY)
The APPS assembly is located at the top-left-front
of the engine. A plastic cover is used to cover the
assembly. The actual sensor is located behind its
mounting bracket.
DESCRIPTION (LATE)
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.
OPERATION
The Accelerator Pedal Position Sensor (APPS) is a
linear potentiometer. It provides the Engine Control
Module (ECM) with a DC voltage signal proportional
to the angle, or position of the accelerator pedal.
REMOVAL
Early Diesel Engines
The APPS is serviced (replaced) as one assembly
including the lever, brackets and sensor. The APPS is
calibrated to its mounting bracket. The APPS assem-
bly is located at left-front of engine below plastic
cable/lever/linkage cover (Fig. 1).
DRFUEL INJECTION - DIESEL 14 - 79

CAUTION: Do not attempt to remove sensor from
its mounting bracket as electronic calibration will
be destroyed (sensor-to-bracket mounting screws
are permanently attached). Two accelerator lever
set screws (Fig. 3) are used to position lever. Do
not attempt to alter positions of these set screws as
electronic calibration will be destroyed.
(1) Disconnect both negative battery cables at both
batteries.
(2) Remove cable cover (Fig. 1). Cable cover is
attached with 2 Phillips screws, 2 plastic retention
clips and 2 push tabs (Fig. 1). Remove 2 Phillips
screws and carefully pry out 2 retention clips. After
clip removal, push rearward on front tab, and
upward on lower tab for cover removal.
(3) Using finger pressure only, disconnect end of
speed control servo cable from throttle lever pin by
pulling forward on connector while holding lever
rearward (Fig. 2).DO NOT try to pull connector
off perpendicular to lever pin. Connector will
be broken.
(4) Using two small screwdrivers, pry throttle
cable connector socket from throttle lever ball (Fig.
2).Be very careful not to bend throttle lever
arm.
(5) Disconnect transmission control cable at lever
arm (if equipped). Refer to 21, Transmission.
(6) Squeeze pinch tabs on speed control cable (Fig.
2) and pull cable rearward to remove from cable
mounting bracket.
(7) Squeeze pinch tabs on throttle cable (Fig. 2)
and pull cable rearward to remove from cable mount-
ing bracket.
(8) If equipped with an automatic transmission,
refer to 21, Transmission for transmission control
cable removal procedures.
(9) Disconnect wiring harness clip (Fig. 3) at bot-
tom of bracket.
(10) Remove 6 mounting bolts (Fig. 3) and par-
tially remove APPS assembly from engine. After
assembly is partially removed, disconnect electrical
connector from bottom of sensor by pushing on con-
nector tab (Fig. 4).
(11) Remove APPS assembly from engine.
Late Diesel Engines
The APPS is serviced (replaced) as one assembly
including the sensor, plastic housing and cable. The
APPS assembly is located under the left vehicle bat-
tery tray (Fig. 5). 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. 6). Disconnect electri-
cal connector.
(5) Remove 3 mounting bolts (Fig. 6).
(6) Remove APPS assembly from battery tray.
Fig. 1 CABLE/LEVER/THROTTLE LINKAGE COVER
1 - CABLE/LEVER/LINKAGE COVER
2 - PUSH UP LOWER TAB
3 - SCREWS/CLIPS (2)
4 - TAB PUSH HERE
Fig. 2 SERVO CABLE AT THROTTLE LEVER
1 - PINCH (2) TABS
2 - CABLE MOUNTING BRACKET
3 - PINCH TABS (2)
4 - OFF
5 - THROTTLE CABLE
6 - THROTTLE LEVER
7 - THROTTLE LEVER PIN
8 - OFF
9 - CONNECTOR
10 - SPEED CONTROL CABLE
14 - 80 FUEL INJECTION - DIESELDR
ACCELERATOR PEDAL POSITION SENSOR (Continued)

INSTALLATION
Early Diesel Engines
The APPS is serviced (replaced) as one assembly
including the lever, brackets and sensor. The APPS is
calibrated to its mounting bracket.
(1) Snap electrical connector into bottom of sensor.
(2) Position APPS assembly to engine and install 6
bolts. Tighten bolts to 24 N´m (18 ft. lbs.) torque.
(3) Connect wiring harness clip at bottom of
bracket.
(4) If equipped with an automatic transmission,
refer to Group 21, Transmission for transmission con-
trol cable installation procedures.
(5) Install speed control cable into mounting
bracket. Be sure pinch tabs have secured cable.
(6) Install throttle cable into mounting bracket. Be
sure pinch tabs have secured cable.
(7) Connect throttle cable at lever (snaps on).
(8) Connect speed control cable to lever by pushing
cable connector rearward onto lever pin while hold-
ing lever forward.
(9) Install cable cover.
(10) Connect both negative battery cables to both
batteries.
(11)ECM Calibration:Turn key to ON position.
Without starting engine, slowly press throttle pedal
to floor and then slowly release. This step must bedone (one time) to ensure accelerator pedal position
sensor calibration has been learned by ECM. If not
done, possible DTC's may be set.
(12) Use DRB III scan tool to erase any DTC's
from ECM.
Late Diesel Engines
(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.
(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 cables to both bat-
teries.
(b) Turn key switch ON, but do not crank
engine.
(c) Leave key switch ON for a minimum of 10
seconds. This will allow ECM to learn electrical
parameters.
(8) If necessary, use DRB IIItScan Tool to erase
any Diagnostic Trouble Codes (DTC's) from PCM.CAMSHAFT POSITION
SENSOR
DESCRIPTION
The Camshaft Position Sensor (CMP) on the 5.9L
diesel engine is located below the fuel injection
pump. It is bolted to the back of the timing gear
cover.
OPERATION
The diesel Camshaft Position Sensor (CMP) con-
tains a hall effect device. A rotating target wheel
(tonewheel) for the CMP is located on the front tim-
ing gear. This hall effect device detects notches
located on the tonewheel. As the tonewheel rotates,
the notches pass the tip of the CMP.
When the leading edge of the tonewheel notch
passes the tip of the CMP, the following occurs: The
interruption of magnetic field causes the voltage to
switch high resulting in a signal of approximately 5
volts.
When the trailing edge of the tonewheel notch
passes the tip of the CMP, the following occurs: The
change of the magnetic field causes the signal voltage
to switch low to 0 volts.
Fig. 7 APPS CABLE (LATE)
1 - APPS LEVER
2 - BALL SOCKET
3 - SWING-DOWN DOOR
4 - CABLE CLIP
5 - CABLE
14 - 82 FUEL INJECTION - DIESELDR
ACCELERATOR PEDAL POSITION SENSOR (Continued)

COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION..........................6
DIAGNOSIS AND TESTING - STEERING
COLUMN.............................7
REMOVAL.............................7
INSTALLATION..........................9
IGNITION SWITCH
DESCRIPTION..........................9
OPERATION............................9
DIAGNOSIS AND TESTING - IGNITION
SWITCH.............................9
REMOVAL.............................10
INSTALLATION.........................11
KEY-IN IGNITION SWITCH
DESCRIPTION.........................11
DIAGNOSIS AND TESTING - IGNITION
SWITCH AND KEY LOCK CYLINDER.......11
KEY CYLINDER
REMOVAL.............................12INSTALLATION.........................12
GEAR SHIFT LEVER
REMOVAL.............................12
INSTALLATION.........................12
UPPER STEERING COUPLING
REMOVAL.............................13
INSTALLATION.........................14
LOWER STEERING COUPLING
REMOVAL
REMOVAL - ALL LD & HD EXCEPT 4X4 HD . 14
REMOVAL - 4X4 HD...................14
INSTALLATION
INSTALLATION - ALL LD & HD EXCEPT 4X4
HD.................................15
INSTALLATION - 4X4 HD................15
STEERING WHEEL
REMOVAL.............................15
INSTALLATION.........................15
COLUMN
DESCRIPTION
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.
The tilt and standard column (Fig. 1) has been
designed to be serviced as an assembly; less wiring,
switches, shrouds, steering wheel, etc. Most steering
column components can be serviced without remov-
ing the steering column from the vehicle.
To service the steering wheel, switches or airbag,
refer to Restraints and follow all WARNINGS and
CAUTIONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG ANDPOSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Do not hammer on steering column
shaft. This may cause damage to the shaft or bear-
ing.
CAUTION: Do not attempt to remove the pivot bolts
to disassemble the tilting mechanism. Do not
remove shaft lock plate or plate retainer. This will
damage the column.
CAUTION: Do not attempt to remove or modify the
park lock slider or link.
NOTE: When servicing the steering wheel after
removing the old bolt a new bolt must be used
when installing.
19 - 6 COLUMNDR

NOTE: When servicing the coupler a new bolt must
be used when installing.
DIAGNOSIS AND TESTING - STEERING
COLUMN
If the vehicle is involved in a front end collision/the
air bag has deployed the column must be inspected.
This inspection will determine if the Column has col-
lapsed. Inspect the column mounting capsules visu-
ally and manually push and pull them to check for
separation or fractures. If capsules are fractured or
have moved the column MUST be replaced.
REMOVAL
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. REFER TO ELECTRICAL RESTRAINT SYS-
TEM FOR SERVICE PROCEDURES. FAILURE TO DO
SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.
CAUTION: All fasteners must be torqued to specifi-
cation to ensure proper operation of the steering
column.(1) Position the front wheelsstraight ahead.
(2) Disconnect the negative (ground) cable from
the battery.
(3) Remove the two switches from the steering
wheel.
(4) Remove the airbag, (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(5) Remove the steering wheel with special tool
CJ98±1 or an appropriate steering wheel puller.
CAUTION: Ensure the puller bolts are fully engaged
into the steering wheel and not into the clock-
spring, before attempting to remove the wheel. Fail-
ure to do so may damage the steering wheel/
clockspring.
(6) Remove the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - REMOVAL).
(7) Remove the tilt lever.
(8) Remove the column shrouds (Fig. 2).
(9) Remove the clock spring, (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/CLOCKSPRING - REMOV-
AL).
(10) Disconnect the wiring harness to the column.
(11) Remove the shift cable from the column shift
lever actuator (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - 32RH/GEAR SHIFT
CABLE - REMOVAL). (Fig. 3).
Fig. 1 STEERING COLUMN
1 - LOCK CYLINDER
2 - GEAR SHIFT LEVER
3 - MOUNTING HOLES
4 - STEERING COLUMN
5 - TILT LEVER
Fig. 2 UPPER & LOWER SHROUDS
1 - UPPER SHROUD
2 - LOWER SHROUD
DRCOLUMN 19 - 7
COLUMN (Continued)

INSTALLATION
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. REFER TO ELECTRICAL RESTRAINT SYS-
TEM FOR SERVICE PROCEDURES. FAILURE TO DO
SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.
CAUTION: All fasteners must be torqued to specifi-
cation to ensure proper operation of the steering
column.
(1) Position the steering column on the dash panel
support and loosely install the mounting nuts.
(2) Firmly slide the steering column upward
against the studs in dash panel and hand tighten the
nuts.
(3) Install the steering shaft coupler on the steer-
ing shaft and loosely install anewbolt.
(4) Center steering column in dash opening and
tighten mounting nuts to 28 N´m (250 in. lbs.).
NOTE: Torque the upper left nut first then the lower
right nut. Then torque the lower left nut then the
upper right nut.
NOTE: A new bolt must be used for reinstallation.
(5) Tighten the coupler bolt to 57 N´m (42 ft. lbs.).
(6) Install a new brake light switch (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL).(7) Install the shifter cable. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 32RH/GEAR
SHIFT CABLE - INSTALLATION)
(8) Connect the wiring harness to the column.
(9) Install the SKIM module.
(10) Install the clockspring(Refer to 8 - ELECTRI-
CAL/RESTRAINTS/CLOCKSPRING - REMOVAL).
(11) Install the shrouds.
(12) Install the steering column opening cover
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN OPENING COVER - INSTALLA-
TION).
(13) Align the spline on the wheel hub to shaft.
(14) Then install the steering wheel and install a
newbolt. Tighten the bolt to 61 N´m (45 ft. lbs.).
(15) Install the airbag (Refer to 8 - ELECTRICAL/
RESTRAINTS/DRIVER AIRBAG - INSTALLATION).
(16) Install the two steering wheel switches.
(17) Install the tilt lever handle.
(18) Install the negative battery terminal.
(19) Test the operation of the horn, Electronic
PRNDL Indicator, lights and any other functions that
are steering column operated.IGNITION SWITCH
DESCRIPTION
The ignition switch is located on the steering col-
umn. It is used as the main on/off switching device
for most electrical components. The mechanical key
cylinder is used to engage/disengage the electrical
ignition switch.
OPERATION
Vehicles equipped with an automatic trans-
mission and a steering column mounted shifter:
an interlock device is located within the shift cable.
This interlock device is used to lock the transmission
shifter in the PARK position when the key cylinder is
in any position and the brake pedal is not depressed.
DIAGNOSIS AND TESTING - IGNITION SWITCH
TEST AND REPAIR
If the key removal effort is excessive on a vehicle
with a automatic transmission first adjust the shift
linkage, (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 46RE/GEAR SHIFT CABLE -
ADJUSTMENTS).
If the ignition switch effort is excessive remove the
ignition key cylinder from the steering column. (Refer
to 19 - STEERING/COLUMN/LOCK CYLINDER
HOUSING - REMOVAL). Check the turning effort of
the key cylinder. If the ignition key cylinder effort is
excessive replace the key cylinder.
Fig. 7 STEERING COLUMN
1 - Steering Wheel
2 - Key Cylinder
3 - Gear Shift Lever
4 - Steering Column
5 - Tilt Lever Cable
DRCOLUMN 19 - 9
COLUMN (Continued)