2003 DODGE RAM lock

(11) Connect necessary vacuum lines to throttle
body.
(12) Install air resonator mounting bracket near
front of throttle body (2 bolts).
(13) Connect fuel line latch clip and fuel line to
fuel rail. Refer to Quick-Connect Fittings.
(14) Install air box to throttle body.
(15) Install air duct to air box.
(16) Connect battery cable to battery.
(17) Start engine and check for leaks.
4.7L V-8
(1) If fuel injectors are to be installed, refer to Fuel
Injector Removal/Installation.
(2) Clean out fuel injector machined bores in
intake manifold.
(3) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(4) Position fuel rail/fuel injector assembly to
machined injector openings in cylinder head.
(5) Guide each injector into cylinder head. Be care-
ful not to tear injector o-rings.
(6) Pushrightside of fuel rail down until fuel
injectors have bottomed on cylinder head shoulder.
Pushleftfuel rail down until injectors have bot-
tomed on cylinder head shoulder.
(7) Install 4 fuel rail mounting bolts and tighten.
Refer to torque specifications.
(8) Install 8 ignition coils. Refer to Ignition Coil
Removal/Installation.
(9) Connect electrical connectors to throttle body.
(10) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 17). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector.
(11) Connect necessary vacuum lines to throttle
body.
(12) Install air resonator mounting bracket near
front of throttle body (2 bolts).
(13) Connect fuel line latch clip and fuel line to
fuel rail. Refer to Quick-Connect Fittings.
(14) Install air box to throttle body.
(15) Install air duct to air box.
(16) Connect battery cable to battery.
(17) Start engine and check for leaks.
5.7L V-8
(1) If fuel injectors are to be installed, refer to Fuel
Injector Removal/Installation.
(2) Clean out fuel injector machined bores in
intake manifold.
(3) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(4) Position fuel rail/fuel injector assembly to
machined injector openings in intake manifold.(5) Guide each injector into intake manifold. Be
careful not to tear injector o-rings.
(6) Pushrightside of fuel rail down until fuel
injectors have bottomed on shoulders. Pushleftfuel
rail down until injectors have bottomed on shoulders.
(7) Install 4 fuel rail holdown clamps and 4 mount-
ing bolts. Refer to Torque Specifications.
(8) Position spark plug cable tray and cable assem-
bly to intake manifold. Snap 4 cable tray retaining
clips into intake manifold.
(9) Install all cables to spark plugs and ignition
coils.
(10) Connect electrical connector to throttle body.
(11) Install electrical connectors to all 8 ignition
coils. Refer to Ignition Coil Removal/Installation.
(12) Connect electrical connector to throttle body.
(13) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 17). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector.
(14) Connect fuel line latch clip and fuel line to
fuel rail. Refer to Quick-Connect Fittings.
(15) Install air resonator to throttle body (2 bolts).
(16) Install flexible air duct to air box.
(17) Connect battery cable to battery.
(18) Start engine and check for leaks.
5.9L V-8
(1) If fuel injectors are to be installed, refer to Fuel
Injector Removal/Installation.
(2) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(3) Clean out fuel injector machined bores in
intake manifold.
(4) Position fuel rail/fuel injector assembly to injec-
tor openings on intake manifold.
(5) Guide each injector into intake manifold. Be
careful not to tear injector o-ring.
(6) Push therightfuel rail down until fuel injec-
tors have bottomed on injector shoulder. Push the
leftfuel rail down until fuel injectors have bottomed
on injector shoulder.
(7) Install fuel rail mounting bolts. Refer to Torque
Specifications.
(8) Connect electrical connector to intake manifold
air temperature sensor.
(9) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 17). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector.
(10) Install fuel tube (line) at side of fuel rail.
Refer to Quick-Connect Fittings for procedures.
(11) Install air cleaner resonator to throttle body.
(12) Connect battery cable to battery.
DRFUEL DELIVERY - GAS 14 - 19
FUEL RAIL (Continued)

(13) Start engine and check for leaks.
8.0L V-10
(1) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(2) Install injector(s) and injector clip(s) to fuel
rail.
NOTE: The fuel injector electrical connectors on all
10 injectors should be facing to right (passenger)
side of vehicle (Fig. 27).
(3) Position fuel rail/fuel injector assembly to injec-
tor openings on intake manifold.
(4) Guide each injector into intake manifold. Be
careful not to tear injector o-ring.
(5) Push therightfuel rail down until fuel injec-
tors have bottomed on injector shoulder. Push the
leftfuel rail down until fuel injectors have bottomed
on injector shoulder.
(6) Install six fuel rail mounting bolts into lower
half of intake manifold. Tighten bolts to 15 N´m (136
in. lbs.) torque.
(7) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 26). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector. The injector wir-
ing harness is numerically tagged.
(8) Install upper half of intake manifold. Refer to
Engines for procedures.
(9) Connect main fuel line at fuel rail. Refer to
Quick-Connect Fittings for procedures.
(10) Install ignition coil pack and bracket assem-
bly at intake manifold and right engine valve cover
(four bolts).
(11) Install throttle body to intake manifold. Refer
to Throttle Body Removal / Installation.
(12) Install throttle body linkage to throttle body.
(13) Install air cleaner tube and housing.
(14) Install negative battery cable at battery.
(15) Start engine and check for leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module, and (if equipped) cer-
tain ORVR components.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.Two check (control) valves are mounted into the
top of the fuel tank. Refer to Fuel Tank Check Valve
for additional information.
An evaporation control system is connected to the
fuel tank to reduce emissions of fuel vapors into the
atmosphere. When fuel evaporates from the fuel
tank, vapors pass through vent hoses or tubes to a
charcoal canister where they are temporarily held.
When the engine is running, the vapors are drawn
into the intake manifold. Certain models are also
equipped with a self-diagnosing system using a Leak
Detection Pump (LDP) and/or an On-Board Refueling
Vapor Recovery (ORVR) system. Refer to Emission
Control System for additional information.
REMOVAL- EXCEPT DIESEL
Fuel Tank Draining
WARNING: THE FUEL SYSTEM MAY BE UNDER
CONSTANT FUEL PRESSURE EVEN WITH THE
ENGINE OFF. THIS PRESSURE MUST BE
RELEASED BEFORE SERVICING FUEL TANK.
Two different procedures may be used to drain fuel
tank: through the fuel fill fitting on tank, or using
the DRBtscan tool. Due to a one-way check valve
installed into the fuel fill opening fitting at the tank,
the tank cannot be drained conventionally at the fill
cap.
The quickest draining procedure involves removing
the rubber fuel fill hose.
As an alternative procedure, the electric fuel pump
may be activated allowing tank to be drained at fuel
rail connection. Refer to DRB scan tool for fuel pump
activation procedures. Before disconnecting fuel line
at fuel rail, release fuel pressure. Refer to the Fuel
System Pressure Release Procedure for procedures.
Attach end of special test hose tool number 6541,
6539, 6631 or 6923 at fuel rail disconnection (tool
number will depend on model and/or engine applica-
tion). Position opposite end of this hose tool to an
approved gasoline draining station. Activate fuel
pump and drain tank until empty.
If electric fuel pump is not operating, fuel must be
drained through fuel fill fitting at tank. Refer to fol-
lowing procedures.
(1) Release fuel system pressure.
(2) Raise vehicle.
(3) Thoroughly clean area around fuel fill fitting
and rubber fuel fill hose at tank.
(4) If vehicle is equipped with 4 doors and a 6 foot
(short) box, remove left-rear tire/wheel.
(5) Loosen clamp (Fig. 28) and disconnect rubber
fuel fill hose at tank fitting. Using an approved gas
holding tank, drain fuel tank through this fitting.
14 - 20 FUEL DELIVERY - GASDR
FUEL RAIL (Continued)

Tank Removal
(1) Loosen clamp and disconnect rubber fuel vent
hose (Fig. 28) at tank fitting.
(2) Support tank with a hydraulic jack.
(3) Remove 2 fuel tank strap nuts (Fig. 29) and
remove both tank support straps.
(4) Carefully lower tank a few inches and discon-
nect fuel pump module electrical connector (Fig. 30)
at top of tank. To disconnect electrical connector:
Push upward on red colored tab to unlock. Push on
black colored tab while removing connector.(5) Disconnect fuel line at fuel filter / fuel pressure
regulator (Fig. 30) by pressing on tabs at side of
quick-connect fitting.
(6) Disconnect EVAP line at top of tank (Fig. 1).
(7) Continue to lower tank for removal.
(8) If fuel tank is to be replaced, remove fuel pump
module from tank. Refer to Fuel Pump Module
Removal/Installation procedures.
Fig. 28 FUEL TANK FILL / VENT HOSES
1 - BEZEL SCREWS
2 - FUEL FILL BEZEL
3 - HOSE CLAMPS4 - VENT HOSE
5 - FUEL TANK
6 - FILL HOSE
DRFUEL DELIVERY - GAS 14 - 21
FUEL TANK (Continued)

(13) Start engine and check for fuel leaks near top
of module.
INLET FILTER
REMOVAL
The fuel pump inlet filter (strainer) is located on
the bottom of the fuel pump module (Fig. 32). The
fuel pump module is located inside of fuel tank.
(1) Remove fuel tank. Refer to Fuel Tank Removal/
Installation.
(2) Remove fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(3) Remove filter by carefully prying 2 lock tabs at
bottom of module with 2 screwdrivers. Filter is
snapped to module.
(4) Clean bottom of pump module.
INSTALLATION
The fuel pump inlet filter (strainer) is located on
the bottom of the fuel pump module (Fig. 32). The
fuel pump module is located inside of fuel tank.
(1) Snap new filter to bottom of module. Be sure
o-ring is in correct position.
(2) Install fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(3) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
Fig. 30 FUEL PUMP MODULE CONNECTIONS
1 - TOP OF FUEL TANK
2 - FUEL PUMP MODULE
3 - FUEL FILTER / FUEL PRESSURE REGULATOR
4 - ELEC. CONNECT.
Fig. 31 HOSE ALIGNMENT MARKS
1 - ALIGNMENT MARKS (MARK FOR FILL HOSE IS LOCATED
ON FUEL TANK - MARK FOR VENT HOSE IS LOCATED ON
FITTING)
2 - PAINT MARKS ON RUBBER HOSES
Fig. 32 FUEL PUMP INLET FILTER
1 - FUEL PUMP INLET FILTER
2 - LOCK TABS (2)
3 - FUEL PUMP MODULE (BOTTOM)
DRFUEL DELIVERY - GAS 14 - 23
FUEL TANK (Continued)

(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)

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, spaced every 45 degrees, at its outer
edge (Fig. 8).
The notches cause a pulse to be generated when
they pass under the sensor. The pulses are the input
to the PCM. For each engine revolution, there are 8
pulses generated on V-8 engines.
The engine will not operate if the PCM does not
receive a CKP sensor input.
8.0L V-10
The Crankshaft Position (CKP) sensor detects
notches machined into the middle of the crankshaft
(Fig. 9).
There are five sets of notches. Each set contains
two notches. Basic ignition timing is determined by
the position of the last notch in each set of notches.
Once the Powertrain Control Module (PCM) senses
the last notch, it will determine crankshaft position
(which piston will next be at Top Dead Center). An
input from the camshaft position sensor is also
needed. It may take the module up to one complete
engine revolution to determine crankshaft position
during engine cranking.The PCM uses the signal from the camshaft posi-
tion sensor to determine fuel injector sequence. Once
crankshaft position has been determined, the PCM
begins energizing a ground circuit to each fuel injec-
tor to provide injector operation.
Fig. 7 CKP SENSOR OPERATION AND NOTCHES -
5.7L V-8
1 - RIGHT / REAR SIDE OF CYLINDER BLOCK
2 - MACHINED HOLE
3 - NOTCHES
Fig. 8 CKP SENSOR OPERATION ± 5.9L V-8
1 - CRANKSHAFT POSITION SENSOR
2 - NOTCHES
3 - FLYWHEEL
Fig. 9 CKP SENSOR OPERATION ± 8.0L V-10
ENGINE
1 - CRANKSHAFT NOTCHES
2 - CRANKSHAFT
3 - CRANKSHAFT POSITION SENSOR
14 - 28 FUEL INJECTION - GASDR
CRANKSHAFT POSITION SENSOR (Continued)

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) Disconnect sensor electrical connector.
(3) Remove sensor mounting bolt (Fig. 10).
(4) Carefully twist sensor from cylinder block.
(5) Check condition of sensor o-ring.
4.7L V-8
The Crankshaft Position (CKP) sensor is located at
the right-rear side of the engine cylinder block (Fig.
11). It is positioned and bolted into a machined hole
in the engine block.
(1) Raise vehicle.(2) Disconnect CKP electrical connector at sensor.
(3) Remove CKP mounting bolt (Fig. 11).
(4) Carefully twist sensor from cylinder block.
(5) Remove sensor from vehicle.
(6) Check condition of sensor o-ring.
5.7L V-8
The Crankshaft Position (CKP) sensor is located at
the right-rear side of the engine cylinder block (Fig.
12). It is positioned and bolted into a machined hole
in the engine block.
(1) Raise vehicle.
(2) Disconnect CKP electrical connector at sensor
(Fig. 12).
(3) Remove CKP mounting bolt (Fig. 12).
(4) Carefully twist sensor from cylinder block.
(5) Remove sensor from vehicle.
(6) Check condition of sensor o-ring.
Fig. 10 CKP REMOVAL / INSTALLATION - 3.7L
1 - MOUNTING BOLT
2 - CKP SENSOR
3 - O-RING
Fig. 11 CKP REMOVAL / INSTALLATION - 4.7L
1 - CRANKSHAFT POSITION SENSOR
2 - MOUNTING BOLT
DRFUEL INJECTION - GAS 14 - 29
CRANKSHAFT POSITION SENSOR (Continued)

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 wiring harness.
(3) Remove two sensor (recessed hex head) mount-
ing bolts (Fig. 13).
(4) Remove sensor from engine.
8.0L V±10
The crankshaft position sensor is located on the
right-lower side of the cylinder block, forward of the
right engine mount, just above the oil pan rail (Fig.
14).
(1) Raise and support vehicle.
(2) Disconnect sensor pigtail harness from main
engine wiring harness.
(3) Remove sensor mounting bolt (Fig. 15).
(4) Cut plastic tie strap (Fig. 14) securing sensor
pigtail harness to side of engine block.
(5) Carefully pry sensor from cylinder block in a
rocking action with two small screwdrivers.
(6) Remove sensor from vehicle.
(7) Check condition of sensor o-ring (Fig. 16).
INSTALLATION
3.7L V-6
(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.
Fig. 12 CKP REMOVAL / INSTALLATION - 5.7L V-8
1 - CYLINDER BLOCK - RIGHT / REAR
2 - ELEC. CONNECTOR
3 - MOUNTING BOLT
4 - CKP SENSOR
Fig. 13 CKP REMOVAL / INSTALLATION - 5.9L V-8
1 - GROMMET
2 - MOUNTING BOLTS (2)
3 - CRANKSHAFT POSITION SENSOR
4 - RIGHT EXHAUST MANIFOLD
5 - TRANSMISSION BELL HOUSING
Fig. 14 CKP SENSOR LOCATION ± 8.0L V-10
1 - CRANKSHAFT POSITION SENSOR
2 - HOLE
3 - OIL FILTER
4 - PLASTIC TIE STRAP
5 - PIGTAIL HARNESS
14 - 30 FUEL INJECTION - GASDR
CRANKSHAFT POSITION SENSOR (Continued)