2003 DODGE RAM torque

(8) Remove 3 injector rail mounting bolts (Fig. 23).
(9) Remove rail from top of intake manifold.
INSTALLATION
(1) Clean any dirt/debris from top of intake mani-
fold and bottom of fuel rail.
(2) Position fuel rail to top of manifold and install
3 mounting bolts. Tighten 3 bolts to 24 N´m (18 ft.
lbs.) torque.
(3) Install all high-pressure lines to rail. Refer to
Fuel Lines for procedures.
(4) Reposition wiring harness to intake manifold
and install new tie wraps.
(5) Position fuel limiting valve and install banjo
bolt. Tighten bolt to 30 N´m (22 ft. lbs.) torque.
(6) Connect electrical connector to fuel pressure
sensor.
(7) Position 2 positive (+) cables to intake heater
studs. Install 2 nuts.
(8) Connect battery cables to both batteries.
(9) Start engine and check for leaks.
INLET AIR TEMPERATURE
SENSOR/PRESSURE SENSOR
DESCRIPTION
The combination, dual function Inlet Air Tempera-
ture/Pressure Sensor is located on the air cleaner (fil-
ter) cover.
OPERATION
The Inlet Air Temperature/Pressure Sensor is a
combination dual-function sensor. The sensor element
extends into the intake air stream at the top of the
air filter housing. Ambient air temperature as well as
barometric pressure is monitored by this sensor. The
Engine Control Module (ECM) monitors signals from
this sensor.
REMOVAL
The Inlet Air Temperature/Pressure Sensor is
located on the air cleaner cover (Fig. 24).
(1) Disconnect electrical connector at sensor (Fig.
25).
(2) Remove two Torx-type mounting screws.
(3) Remove sensor from air cleaner cover.
(4) Check condition of sensor o-ring (Fig. 26).
INSTALLATION
(1) Check condition of sensor o-ring.
(2) Position sensor into top of air cleaner cover
with a slight twisting action.
(3) Install 2 mounting screws.
(4) Install electrical connector.
Fig. 23 FUEL INJECTOR RAIL
1 - FUEL RAIL MOUNTING BOLTS (3)
2 - INSULATED CLAMPS
3 - FUEL INJECTOR RAIL
Fig. 24 IAT/PRESSURE SENSOR LOCATION - 5.9L
DIESEL
1 - CLIPS
2 - FILTER COVER
3 - FILTER MINDERŸ
4 - INLET AIR TEMPERATURE/ PRESSURE SENSOR
5 - FILTER HOUSING
14 - 90 FUEL INJECTION - DIESELDR
FUEL INJECTOR RAIL (Continued)

INTAKE AIR HEATER
DESCRIPTION
The intake manifold air heater element assembly
is located in the top of the intake manifold.
OPERATION
The air heater elements are used to heat incoming
air to the intake manifold. This is done to help
engine starting and improve driveability with cool or
cold outside temperatures.
Electrical supply for the 2 air heater elements is
controlled by the Engine Control Module (ECM)
through the 2 air heater relays. Refer to Intake Man-
ifold Air Heater Relays for more information.
Two heavy-duty cables connect the 2 air heater ele-
ments to the 2 air heater relays. Each of these cables
will supply approximately 95 amps at 12 volts to an
individual heating element within the heater block
assembly.
Refer to the Powertrain Diagnostic Procedures
manual for an electrical operation and complete
description of the intake heaters, including pre-heat
and post-heat cycles.
REMOVAL
If servicing either of the heater elements, the
entire block/element assembly must be replaced.
(1) Disconnect both negative battery cables at both
batteries. Cover and isolate ends of both cables.
(2) Remove both the intake manifold air intake
tube (above injection pump), and its rubber connector
hose (Fig. 27).
(3) Lift 2 rubber covers (Fig. 28) to gain access to 2
positive (+) cable nuts. Remove these 2 nuts (Fig. 29)
and remove 2 cables from studs.
(4) Disconnect ground strap (Fig. 28) at heater ele-
ment stud.
(5) Remove wiring harness clips.
(6) Remove engine oil dipstick tube bracket from
air inlet connection and fuel filter housing.
(7) Remove 4 housing mounting bolts (Fig. 28) and
remove heater element assembly.
INSTALLATION
If servicing either of the heater elements, the
entire block/element assembly must be replaced.
(1) Using 2 new gaskets, position element assem-
bly and air housing to intake manifold.
(2) Position ground cable to air housing.
(3) Install 4 housing bolts and tighten to 24 N´m
(18 ft. lbs.) torque.
(4) Connect 2 positive (+) heater cables at cable
mounting studs.Do not allow either of the cable
eyelets to contact any other metal source other
than the cable nuts/studs.
Fig. 25 INLET/PRESSURE SENSOR REMOVAL/
INSTALLATION
1 - INLET/PRESSURE SENSOR
2 - ELEC. CONNECTOR
3 - SENSOR MOUNTING SCREWS (2)
4 - TOP OF AIR FILTER COVER
Fig. 26 SENSOR O-RING
1 - IAT/PRESSURE SENSOR
2 - O-RING
DRFUEL INJECTION - DIESEL 14 - 91
INLET AIR TEMPERATURE SENSOR/PRESSURE SENSOR (Continued)

Refer to Powertrain Diagnostic Procedures for an
electrical operation and complete description of the
intake heaters, including pre-heat and post-heat
cycles.
REMOVAL
The 2 intake manifold air heater relays are located
in the engine compartment. They are attached to a
common bracket. This bracket is attached to the
right battery tray (Fig. 30).
The mounting bracket and both relays are replaced
as an assembly.
(1) Disconnect both negative battery cables at both
batteries.
(2) Disconnect four relay trigger wires at both
relays. Note position of wiring before removing.(3) Lift four rubber shields from all 4 cables.
(4) Remove four nuts at cable connectors. Note
position of wiring before removing.
(5) Remove relay mounting bracket bolts and
remove relay assembly.
INSTALLATION
(1) Install relay assembly to battery tray. Tighten
mounting bolts to 4.5 N´m (40 in. lbs.) torque.
(2) Connect eight electrical connectors to relays.
(3) Connect battery cables to both batteries.
INTAKE AIR TEMPERATURE
SENSOR/MAP SENSOR
DESCRIPTION
The combination, dual function Intake Manifold
Air Temperature Sensor/MAP Sensor is installed into
the top of the intake manifold.
OPERATION
The combination, dual function Intake Manifold
Air Temperature Sensor/MAP Sensor is installed into
the top of the intake manifold with the sensor ele-
ment extending into the air stream.
The IAT portion of the sensor provides an input
voltage to the Engine Control Module (ECM) indicat-
ing intake manifold air temperature. The MAP por-
tion of the sensor provides an input voltage to the
ECM indicating turbocharger boost pressure.
REMOVAL
The combination, dual function Intake Manifold
Air Temperature Sensor/MAP (IAT/MAP) sensor is
installed into the top of the intake manifold (Fig. 31).
(1) Clean area around sensor.
(2) Disconnect electrical connector from IAT/MAP
sensor.
(3) Remove two T-15 Torx headed screws.
(4) Remove sensor from intake manifold.
(5) Check condition of sensor o-ring (Fig. 32).
Fig. 30 INTAKE MANIFOLD AIR HEATER RELAYS
1 - BATTERY
2 - CABLES TO INTAKE HEATERS
3 - RELAY TRIGGER WIRES
4 - INTAKE AIR HEATER RELAYS (2)
DRFUEL INJECTION - DIESEL 14 - 93
INTAKE AIR HEATER RELAY (Continued)

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)

(7) Remove the lower steering shaft coupler (Fig.
20).
INSTALLATION
INSTALLATION - ALL LD & HD EXCEPT 4X4
HD
(1) Install the coupler to the steering rack & pin-
ion using the marks made in the removal process.
(2) Install the coupler to the intermediate shaft
using the marks made in the removal process.
NOTE: New pinch bolts must be used for reinstalla-
tion.
(3) Install the lower pinch bolt and tighten to 57
N´m (42 ft. lbs.).
(4) Install the upper pinch bolt and tighten to 57
N´m (42 ft. lbs.).
(5) Install the left front tire and wheel assembly
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(6) Lower the vehicle.
(7) Reconnect the negative battery cable.
(8) Unlock the steering wheel.
INSTALLATION - 4X4 HD
(1) Install the coupler to the steering gear.
(2) Install the coupler to the intermediate shaft.
NOTE: New pinch bolts must be used for reinstalla-
tion.
(3) Install the lower pinch bolt and tighten to 28
N´m (250 in. lbs.).
(4) Install the upper pinch bolt and tighten to 57
N´m (42 ft. lbs.).(5) Install the left front tire and wheel assembly
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(6) Lower the vehicle.
(7) Reconnect the negative battery cable.
(8) Unlock the steering wheel.
STEERING WHEEL
REMOVAL
(1) Disable and remove the driver's side air-
bag.(Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - REMOVAL).
(2) Partially remove the steering wheel bolt and
leave the bolt in the column.
(3) Install puller CJ98-1 or equivalent using the
top of the bolt to push on. (Fig. 21)
(4) Remove and discard the steering wheel bolt.
(5) Remove the steering wheel.
INSTALLATION
NOTE: Do not reuse the old steering wheel bolt (a
new bolt must be used)
(1) Install steering wheel to the column
NOTE: Be certain that the steering wheel mounting
bolt is tightened to the proper torque specification
to ensure proper clockspring operation.
(2) Install the new steering wheel bolt. Tighten the
bolt to 61 N´m (45 ft. lbs.).
(3) Install the driver's side air bag. (Refer to 8 -
ELECTRICAL/RESTRAINTS/DRIVER AIRBAG -
INSTALLATION).
Fig. 20 INTERMEDIATE STEERING SHAFT
1 - UPPER COUPLING BOOT AND BOLT
2 - INTERMEDIATE STEERING SHAFT
3 - LOWER COUPLING BOLT
4 - STEERING GEAR
Fig. 21 STEERING WHEEL PULLER
1 - STEERING WHEEL
2 - SPECIAL TOOL CJ98-1
DRCOLUMN 19 - 15
LOWER STEERING COUPLING (Continued)

GEAR - INDEPENDENT FRONT SUSPENSION
TABLE OF CONTENTS
page page
GEAR - INDEPENDENT FRONT SUSPENSION
DESCRIPTION.........................16
REMOVAL.............................16
INSTALLATION.........................17
SPECIFICATIONS
TORQUE CHART......................18BUSHING
REMOVAL.............................18
INSTALLATION.........................18
GEAR - INDEPENDENT FRONT
SUSPENSION
DESCRIPTION
A rack and pinion steering gears (Fig. 1) is made
up of two main components, the pinon shaft and the
rack. The gear cannot be adjusted or internally ser-
viced. If a malfunction or a fluid leak occurs, the gear
must be replaced as an assembly.
REMOVAL
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.
(1) Lock the steering wheel.(2) Drain and siphon the power steering fluid from
the reservoir.
(3) Raise the vehicle.
(4) Remove and discard the steering coupler pinch
bolt.
(5) Remove the power steering hoses from the rack
& pinion.
(6) Remove the tire and wheel assembly.
(7) Remove the tie rod end nuts and separate tie
rod ends from the knuckles with Special tool 8677
(Refer to 19 - STEERING/LINKAGE/TIE ROD END -
REMOVAL).
(8) Remove the skid plate (Refer to 13 - FRAME &
BUMPERS/FRAME/FRONT SKID PLATE - REMOV-
AL).
(9) Remove the rack & pinion mounting bolts. (Fig.
2) & (Fig. 3)
(10) Remove the rack & pinion from the vehicle.
Fig. 1 STEERING GEAR
1 - OUTER TIE ROD ENDS
2 - MOUNTING BUSHINGS
3 - BELLOWS
Fig. 2 STEERING GEAR MOUNTING BOLTS
1 - STEERING GEAR MOUNTING BOLTS 4X4
19 - 16 GEAR - INDEPENDENT FRONT SUSPENSIONDR

SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Rack and Pinion Steering
Gear
Gear to Frame Bolts319 235 Ð
Rack and Pinion Steering
Gear
Coupler Bolt49 36 Ð
Tie Rod End
Knuckle Nut61
Then tighten an additional
90É45
Then tighten an additional
90ÉÐ
Tie Rod End
Jam Nut75 55 Ð
Power Steering Line
Pressure Line32 23 Ð
Power Steering Line
Return Line71 52 Ð
Power Steering Line
Pressure Line To Pump37 27 Ð
BUSHING
REMOVAL
(1) Remove the steering gear (Refer to 19 -
STEERING/GEAR - REMOVAL).
CAUTION: Do not overtighten the vise on the gear
case.
(2) Mount the steering gear in a soft jawed vise.
NOTE: If the bushings are seized a brass punch can
be used to remove the bushings from the gear
using care not to strike the gear.
(3) Remove the front mounting bushings.
(4) Remove the rear mounting bushings.
(5) Remove the steering gear from the vise and
place it on the bench.
INSTALLATION
NOTE: Coat all bushings with a thin rubber lubri-
cate oil prior to installation.
NOTE: A rubber mallet can be used to assist in the
installation of the bushings once lubricated.
(1) Coat the rear bushings with a thin rubber
lubricate oil then install the rear bushings using a
rubber mallet to seat the bushings in the gear.
(2) Coat the front bushings with a thin rubber
lubricate oil then install the front bushings using a
rubber mallet to seat the bushings in the gear.
(3) Install the steering gear (Refer to 19 - STEER-
ING/GEAR - INSTALLATION).
(4) Adjust the toe position (if necessary) (Refer to 2
- SUSPENSION/WHEEL ALIGNMENT - STAN-
DARD PROCEDURE).
19 - 18 GEAR - INDEPENDENT FRONT SUSPENSIONDR
GEAR - INDEPENDENT FRONT SUSPENSION (Continued)